REQUEST FOR PROPOSAL For - ISRO · REQUEST FOR PROPOSAL For SUPPLY, ERECTION, TESTING AND COMMISSIONING OF CONTROL & DATA ACQUISITION SYSTEMS FOR BLAST ... Purchaser reserve right

AUTOMATION SYSTEM FOR HARDWARE INSULATION &LINING SDSC SHAR, ISRO

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SDSC SHAR, Sriharikota

REQUEST FOR PROPOSAL

For

SUPPLY, ERECTION, TESTING AND COMMISSIONING OF CONTROL & DATA ACQUISITION SYSTEMS FOR BLAST

CLEANING, DEGREASING AND RESIN LINING MACHINES AS PER DRAWINGS AND TECHNICAL SPECIFICATION

DOCUMENTS.

Satish Dhawan Space Centre SHAR

Indian Space Research Organization

Sriharikota -524 124, A.P


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Acronyms

ISRO Indian Space Research Organization

SDSC Satish Dhawan Space Centre

CISF Central Industrial Security Force

HIL Hardware Insulation Lining Facility

MCC ( Motor Control centre )

PLC Programmable Logic Control

HF High Frequency

LC Letter of Credit

GA(drawing) General Arrangement ( drawing )

SS Stainless Steel

IP Ingress Protection

UPS Uninterrupted Power Supply

RFP Request for Proposal


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PROPOSAL DOCUMENT, CLARIFICATION AND ADDENDUM

Proposals are invited from the interested Suppliers for the enclosed scope of work in two part bid. Part-1 Technical and Unpriced part of the work and Part-2 Priced Commercial part.

The RFP document is organized in three sections as follows.

Section – 1 General Term and Conditions of the Contract

Section – 2 Scope of Work

Section – 3 Technical Specifications of Instrumentation & Control System Requirements for Grit Blast Cleaning, Degreasing and Resin Lining processes of PSOM-XL & S139 segments at SPP.

Title of the Entity: SDSC SHAR, SRIHARIKOTA

Title of the proposal: SUPPLY, ERECTION, TESTING AND COMMISSIONING OF CONTROL & DATA ACQUISITION SYSTEMS FOR BLAST CLEANING, DEGREASING AND RESIN LINING MACHINES AS PER DRAWINGS AND TECHNICAL SPECIFICATION DOCUMENTS.

Date Public Notification issued :

Last Date of purchase / downloading tender Document :

Last date of submission of tender documents :

Place of submission of tender documents : SDSC SHAR, Sriharikota


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PREPARATION OF BIDS- INFORMATION TO BIDDERS

1.1. SITE VISIT

The Supplier may visit SDSC SHAR and acquaint himself fully with the requirements

before submitting the tender. Supplier shall be deemed to have clearly understood and

satisfied himself regarding the work and services, all conditions liable to be encountered

during the execution

1.2. VALIDITY OF OFFER

Bid shall remain valid for acceptance for a period of 6 (Six) months from the due date of

submission of the Bid. The Supplier shall not be entitled during the said period to revoke

or cancel his Bid or to vary the Bid except and to the extent required by Purchaser and

communicated in writing. Bid shall be revalidated for extended period as required by

Purchaser in writing. In such cases, unless otherwise specified, it is understood that

validity is sought and provided without varying either the quoted price or any other terms

and conditions of Bid finalized till that time.

1.3. COST OF BIDDING

All direct and indirect costs associated with the preparation and submission of Bid

(including clarification meetings and site visit, if any), shall be to Supplier's account and

the Purchaser will in no case be responsible or liable for those costs, regardless of the

conduct or outcome of the Bid process.

1.4. SCHEDULE OF PRICES

The schedule of prices shall be read in conjunctio n with all the sections of

proposal document.

For Lumpsum contract, the lumpsum prices quoted by the Supplier shall be firm

and fixed for the completion of the work, unless st ated otherwise. The price must

be filled in the format for ‘Schedule of Prices’ An nexure-V.

1.5. DOCUMENTS COMPRISING THE BID

PART – I TECHNICAL AND UNPRICED COMMERCIAL PART

Technical bid shall be submitted online and the following documents shall be attached

along with the technical bid. No attachment with price information shall be attached along

with the technical bid.


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(a) Submission of bid letter along with one set of proposal document duly signed

and stamped as token of acceptance

(b) Copy of Company’s registration number certifica te.

(c) Power of attorney in favour of authorized signa tory of the bid / proposal

documents.

(d) All the annexures enclosed in proposal duly fil led, signed and sealed

(e) Unpriced copy of schedule of prices with all ot her commercial terms and

conditions duly filled (Prices to be kept blank), s igned and stamped (Section

2-A Schedule of prices)

(f) Data sheets for all the equipment & checklists enclosed in proposal duly

filled, signed, & stamped.

(g) Technical details, equipment general arrangemen t drawings with part list,

catalogue, layout drawings, P & I diagram, catalogu es etc as applicable and

any other drawing, document as mentioned in the pro posal.

(h) Audited balance sheet including profit and loss account for the last three

financial years showing annual turn-over.

(i) Latest income tax clearance certificate.

(j) Latest solvency certificate from a scheduled ba nk.

(k) List of projects in hand & completed during the last 3 financial year indicating

the name of client, contact person, contract value, nature of work, work

completed, work balance, name of Consultant, month & year of

commencement & completion etc.

(l) Organization chart for the proposed work with b io data of key personnel

(m) Schedule Bar chart.

(n) Execution Plan.

(o) Any other relevant document, Supplier desires t o submit.

(p) The bidder shall furnish a list of all critical items / sub-assemblies along with

offer which are bought out by the bidder and propos ed to be used , along with

necessary details such as manufacturer’s name , bra nd, model no etc.

(Indicative list with preferred make is given in An nexure – II )


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2. PRE-QUALIFICATION CRITERIA

(Tenderer shall submit the following information along with the unpriced techno-commercial bid.)

Sl. No

CRITERIA Vendor Compliance

(YES*/NO)

2.1. Tenderer shall have at least 5 years experience in the field of design, supply and erection & commissioning of Automation of mechanical systems using PLCs using latest SCADA programming.

2.2. Tenderer shall have Configured, Designed, Tested and Erected &

Commissioned at least three Automation systems of value more than

Rs. 20 lakhs or equivalent foreign currency during last five years

Or

Tenderer shall have Configured, Designed, Tested and Erected &

Commissioned at least one Automation systems of value more than

Rs. 50 lakhs or equivalent foreign currency during last five years

2.3. Average annual financial turnover of the tenderer during the last three years, should not be less than Rs.120 lakhs INR or equivalent amount in foreign currency and it should be supported by Audited Annual Financial Accounts Report.

2.4. Copies of the completion certificate/performance certificate and one reference for contact from your client organization shall be furnished. Performance demonstration of similar kind of projects supplied by tenderer at manufacturer site shall be arranged, if called. Purchaser reserve right to evaluate vendor & its sub contractor capability and reject, if found not capable.

2.5. Tenderer shall submit other information in the enclosed vendor evaluation format. The bid submitted without the evaluation format will not be considered for evaluation.

3. BID EVALUATION

3.1. The bid which does not satisfy the pre-qualification criteria as mentioned above shall summarily be rejected and shall not be considered for further evaluation. SDSC SHAR will scrutinize bids to determine whether the bid is substantially responsive to the requirements of the tender documents. For the purpose of this clause, a substantially responsive bid is one which inter-alia conforms to all the terms and conditions of the entire Tender document without any deviations and reservations. The decision of purchaser shall be final in this regard.


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3.2. The offer should be for complete scope of work as specified in tender document. Part/Spilt

offer is NOT acceptable.

3.3. During evaluation, purchaser may request Supplier for any clarification on the bid upon

additional documents which is to be complied with; otherwise offer will be deemed

incomplete.

3.4. Techno-commercial discussion shall be arranged with Supplier, if needed. Supplier shall

depute his authorized representatives for attending discussions. The representatives attending

the discussions shall produce authorization from his organization to attend the discussion and

sign minutes of meeting on behalf of his organization if required. The authorized representative

must be competent and empowered to settle/decide on all technical and commercial issues.

3.5. The complete scope of work is defined in the Proposal document. Only those Suppliers who

undertake total responsibility for the complete scope of work as defined in the Proposal

document shall be considered.

3.6. In case Bid does not fully comply with the requirement of Proposal document and the Supplier

stipulates deviations to the clauses of the proposal in Schedule of deviations, which are

unacceptable to the Purchaser, the Bid will be rejected.

3.7. Performance of Supplier on similar works executed/ under execution shall be taken into

consideration before selecting the Supplier for opening his price bid.

3.8. Purchaser reserves right to visit client’s site for verification/validation.

3.9. The time schedule for completion is given in the Proposal document. Supplier is required to

confirm the completion period unconditionally.

3.10. Purchaser reserves the right to accept a bid other than a lowest and to accept or reject

any bid in full or part without assigning any reasons. Such decisions by the Purchaser shall

bear no liability on the Purchaser whatsoever consequent upon such decision.

3.11. Purchaser shall not be obliged to furnish any information / clarification to unsuccessful

Suppliers as regards to non acceptance of their Bids.


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4. Vendor Evaluation Format Tenderer shall submit the following information along with the unpriced techno-commercial bid.

S. No Description Vendor Response

1. Name of the company :

2. Type of the Company

(Proprietary/Pvt.Ltd/Public Ltd/Joint Venture/Consortium)

:

3. Registration number & certificate :

4. Name & Address of the Office of the Chief Executive of the Company

:

5. Contact person for this tender with name & address and contact number

:

6. From which year the Company is in operation

:

7. IT returns for the last 3 years :

8. Financial parameters :

In Rs. Lakhs only 2012-13 2013-14 2014-15

Turnover ` in lakhs :

Profit/Loss in Rs. lakhs :

9. Details of availability of design and analysis software

Software No. of licenses

No. of Persons

familiar to work on software


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S. No Description Vendor Response

10. Details of availability of machinery and Testing equipments

Machine Type

Qty No. of Persons familiar to work

11. Manpower details

Description No. of Persons

Remarks

Design & Analysis

Technicians

Engr / Supervisor

12. The major customers for whom similar works are provided (Enclose copies of the Purchase Orders)

:

13. Any customers feedback on the services which is in writing (Pl. enclose copies)

:

14. Details of last 5 years experience of contractor in executing similar type of work which are completed

Sl. No

Full postal address of the client

with Contact Person

Description of the work

Value of the work (Rs. in Lakhs)

Completion Time as per

PO

Actual period of

completion

Reasons for delay

1

2


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3

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Note: In order to consider as valid experience, all the experience has to be supported with the

completion certificate and purchase order

15. Details of present works being executed by the contractor

Sl. No Full postal address of the client with Contact Person

Description of the work Value of the work (Rs. in Lakhs)

Note: copy of purchase orders may be enclosed.

Signature of Authorized Person with Seal

5. DOCUMENTS COMPRISING THE BID

PART – II PRICED COMMERCIAL BID

Commercial bid shall be filled in on line and no scanned copy should be attached to

technical bid. No deviations, terms and conditions, assumptions, conditions, discounts etc.

shall be stipulated in price bid. Purchaser will not take cognizance of any such statement

and may at their discretion reject such bids.


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SECTION -1

GENERAL TERMS AND CONDITIONS OF CONTRACT


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1. INTRODUCTION

SDSC SHAR invites tenders in sealed covers from reputed firms with proven ability for SUPPLY, ERECTION, TESTING AND COMMISSIONING OF CONT ROL & DATA ACQUISITION FOR BLAST CLEANING, DEGREASING AND RESIN LINING MACHINES AS PER DRAWINGS AND TECHNICAL SPECIFICATIO N DOCUMENTS for SDSC SHAR, Sriharikota.”

2. SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

The detailed scope of work and technical specifications are given in Section 3 of RFP

document. The general terms and conditions are given below.

3. SUPPLIER's OBLIGATIONS & FUNCTIONS

3.1. SPECIFICATIONS AND DRAWINGS

The Supplier shall execute the works in compliance with the provisions of CONTRACT, good

engineering practices and code requirements.

3.2. APPROVAL OF TECHNICAL DOCUMENTS / DRAWINGS

Supplier shall prepare and submit the following Documents to SDSC SHAR from the

award of Purchase order for clearance.

3.2.1. Party shall produce the schedule of drawings and documents to be submitted for review, approval and information with submission date.

3.2.2. Party shall produce the configuration drawings for SHAR approval

3.2.3. Party shall convey Quality Assurance Plan (QAP). The QAP shall list down various stages of inspection and inspection agency namely supplier quality Control agency & 3rd party inspection agency, if engaged. Elaborate Quality Assurance Plan ( QAP) is to be prepared & furnished for review & approval

3.2.4. Detailed equipment list and bill of materials

3.2.5. Supply of all required information for Design and configuration of Data Acquisition & Control System Interface and related equipments.

3.2.6. Operational Philosophy and Control logic for DACS along with list of all the software licenses and PC specification.

3.2.7. Instrument data sheets, loop diagrams and installation sketches with erection bill of materials.

3.2.8. Layout of Control Panel showing PLC modules, DCPS, and other instruments with construction details, foundation details and interior G.A. drawings.

3.2.9. Front facia layout of Operator Panel as per G.A. drawings.

3.2.10. Instrument list with Makes and Model nos, Service and Type of Instruments.


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3.2.11. Control wiring diagrams indicating terminal details of each components, power supply distribution scheme and bill of quantities of all panel mounted instruments for control panels.

3.2.12. Configuration of SCADA system.

3.2.13. Cable Schedule and Interconnection Schedule.

3.2.14. Electrical wiring diagrams showing interlocks, controls, wiring sizes, rating of each electrical component etc. and logic diagrams

3.2.15. Dimensioned general arrangement and section drawings of switchgear panel

3.2.16. Detailed description of operating sequence and control and interlock system

3.2.17. No activity shall be executed unless Purchaser’s approval is obtained. The above documents / drawings shall be submitted in a format approved by Purchaser. Quality Assurance Plan shall be strictly in accordance with Quality Control Manual and Formats to be provided after the award of CONTRACT.

3.3. DESIGN & SUPPLY OF AUTOMATION SYSTEM.

3.3.1. Design, Supply, Testing, erection, Integration and commissioning of the Automation Systems for the three machines and Data Acquisition and Control system shall be as per Section 3,

3.3.2. Any item which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be supplied and erected at no extra cost, unless otherwise specifically excluded as indicated.

3.3.3. All these goods or material shall be supplied or used shall be new and of first quality. Where imported or partly imported goods or material are offered or intended to be used, the fact must be specifically stated and brought to the notice of Purchaser.

3.4. INSPECTION AND TESTING

3.4.1 As per the procedures detailed in Section 3.

3.4.2 The supplier shall identify various stages of inspection and quality control of the

automation system including sub systems, components and bought out items etc., and

inform the same to SDSC, SHAR in advance. The approved QAP shall be followed

during course of Supply, Erection & Testing.

3.4.3 Purchaser reserves the right to inspect all phases of Supplier’s operations through its

representatives and/or third party inspection agency approved by the Purchaser. Therefore

it is the responsibility of the supplier to provide the necessary support for the inspection

agency and get the works inspected at all stages of work as identified in quality assurance

plan. The presence or absence of a Purchaser’s representative does not relieve the

Supplier of the responsibility for quality control in all phases of the work. In the event

that any of the work being done by the Supplier or any Sub-Supplier is found by

Purchaser’s representatives to be unsatisfactory or not in accordance with the drawings,


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procedures, specifications, and standards the Supplier shall, upon verbal notice of such

discrepancy or deficiency, take immediate steps to revise the work in a manner to

conform to the relevant drawings, procedures and specifications. The Supplier shall carry

out required supervision and inspection as per Quality Assurance Plan and furnish all

assistance required by the Purchaser in carrying out inspection work during this phase.

3.4.4 The authorized inspectors of the purchaser shall have access to the premises of the

supplier and its sub-contractors at all reasonable times. All the equipments, instruments,

tools that are necessary for the inspection shall be provided by the supplier on demand by

purchaser’s own inspectors or a third party authorized by purchaser .Inspection by

purchaser’s own inspectors or by third party authorized by purchaser shall not absolve the

responsibility of the supplier from proper performance of the system and from the

guarantee/warranty clauses stipulated in the contract.

3.4.5 Pre - delivery Inspection: As per the procedures detailed in Section 3.

3.5. DELIVERY AND STORAGE

3.5.1 Dispatch Instructions given in the Contract shall be strictly followed. Failure to comply

with the instructions may result in delay in payment apart from imposing any other

charges as may be deemed to fit.

3.5.2 The Supplier shall be responsible for transporting all the equipment to site, unloading and

storage. No equipment shall be delivered without obtaining dispatch clearance from

Purchaser. All the equipment shall be properly packed to avoid any damage during

transportation / handling / storage.

3.5.3 Party shall undertake the responsibility of the system and its components during

transportation to Sriharikota and during erection, testing and commissioning of the same

at suitable location identified by SDSC, SHAR and until handing over the system to

SDSC, SHAR after its acceptance.

4. INSTALLATION

4.1. GENERAL

4.1.1 Supplier’s staff shall include adequate number of competent erection engineers with

proven experience on similar works to supervise the erection works and sufficient skilled,

unskilled and semiskilled labour to ensure completion of work in time.

4.1.2 Supplier's erection staff shall arrive at site on date agreed by Purchaser. Prior to

proceeding to work, Supplier shall however, first ensure that required/sufficient part of

his supply has arrived at site.


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4.1.3 Certain material handling equipments are available with purchaser and the same shall be

extended free of cost for carrying out unloading and erection at purchaser’s site. However

party shall convey the list of material handling equipments needed for the above purpose.

If the required material handling equipments is found unavailable, the supplier shall has

to arrange the same by its own.

4.1.4 Erection of equipment may be phased in such a manner so as not to obstruct the work

being done by Other Suppliers and / or operating staff that may be present at that time.

4.1.5 During erection, Purchaser's engineer will visit site from time to time with or without

Supplier’s engineer to establish conformity of the work with specification. Any

deviations, deficiencies or evidence of unsatisfactory workmanship shall be corrected as

instructed by Purchaser.

4.1.6 Supplier shall carry out work in a true professional manner and strictly adhere to the

approved drawings. Any damage caused by Supplier during erection to new or existing

building shall be made good at no extra cost to Purchaser.

4.2. RECORDS

Supplier shall maintain records pertaining to the quality of erection work in a format approved

by Purchaser. Whenever erection work is complete, Supplier shall offer erected equipment for

inspection to Purchaser's engineer who along with Supplier's engineer will sign such records

on acceptance.

The complete project, right from component level till the complete system performance tested

including sub – assembly shall be properly documented with drawing, configuration drawings,

Test certificate etc.

There shall be time to time submission of information /clearance / approval by the purchaser

and all comments shall be duly incorporated.

All such drawing will become part of PRODUCTION MASTER FILE which shall also

contain as built drawing, Final Erection, Testing & Commissioning report done at site.

3 copies of PRODUCTION MASTER FILE shall be supplied.

4.3. EQUIPMENT ERECTION

4.3.1 Supplier shall carry out the works in accordance with the specific instructions given on

the approved drawings/ documents or as directed by Purchaser.

4.3.2 Supplier shall take utmost care while handling instruments, delicate equipments, panels

etc., and protect all such equipments on erection.


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5. DRAWINGS AND O&M MANUALS

5.1. Supplier shall submit 3 hard copies & one soft copy of all the approved drawings incorporating

any modification / changes made during the execution of CONTRACT. All these drawings

shall be marked as 'As Built'.

5.2. Supplier shall submit 3 hard & 1 soft copy of the following documents.

5.2.1 Operations manual of the machine.

5.2.2 Programs manual.

5.2.3 Maintenance manual with drawings, circuit diagrams, interfacing instructions, trouble

shooting and maintenance instructions and spares list with source of supply.

5.2.4 Manuals of PLC, PC and major elements from the original equipment manufacturer

(OEM) or supplier.

5.2.5 PLC /SCADA back up in CD/DVD form.

5.2.6 Control system Documents On DVD

5.2.7 Final I&C as-built drawings, software codes and documents must be submitted by the

party.

5.3. Submission of the drawings and manuals shall be a precondition for releasing of any final

payment due to Supplier.

6. TRAINING

Supplier shall organize training for purchaser authorized persons by covering operation and

maintenance of the machine, comprehensive programming at supplier’s premises prior to dispatch

as described in detailed in Section 3. No. of persons - 6 Nos.


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7. SCHEDULE OF PRICE

CONTRACT price shall include all costs of SUPPLY, ERECTION, TESTING AND COMMISSIONING OF CONTROL & DATA ACQUISITION SYSTEM S FOR BLAST CLEANING, DEGREASING AND RESIN LINING MACHINES AS P ER DRAWINGS AND TECHNICAL SPECIFICATION DOCUMENTS.

7.1. Shop floor testing, packing, forwarding, transport to site, unloading, storage, all risk coverage,

erection, commissioning, training, testing & evaluation of equipment including any other cost

for proper and complete execution of the CONTRACT.

7.2. CONTRACT prices shall also include all travelling expenses, living expenses, salaries,

overtime, benefit and any other compensation for engineers, supervisors, skilled, semiskilled

workmen, watch and ward staff, laborer and other staff employed by the Supplier, cost of tools

and tackles required for erection and other consumable material required, and all taxes, duties,

and levies as applicable on the date of submission of bid.

7.3. Price shall be firm & fixed.

7.4. Supplier shall quote the prices as per the price bid format enclosed as section2A-Annexure1

7.5. The rate quoted shall be on FOR SDSC SHAR, Sriharikota basis.

7.6. All rates of taxes/duties/levies applicable with details of percentage and applicable portion

of the price should be spelt out clearly in the offer.

7.7. The taxes applicable for supply and erection & commissioning shall be indicated

separately in terms of percentage in the price bid. If the offers submitted by the suppliers

are silent on taxes, it will be presumed that quoted rates are inclusive of taxes & duties and

no claim in this regard will be entertained later.

7.8. Purchaser is eligible for exemption of Customs Duty for imported items and Excise Duty

for indigenous items. Necessary exemption certificate will be provided to the suppliers

against request. This may be taken into account while quoting for items.

7.9. In order to take care of the currency fluctuations, Tenderers are requested / suggested to quote

imported items in the currency from where it is being imported. If the tenderer quotes imported

items in INR (Indian Rupees) future claim on currency fluctuation shall not be considered.

7.10. In case of foreign suppliers the prices shall be quoted on FOB/

FCA basis. In case of any change, supplier shall identify the Indian agent and responsibilities

related to clearing the consignment, transport of equipment to destination and erection &

commissioning at site and all the necessary works till the equipment is commissioned and

accepted by Purchaser as per the mutually agreed acceptance plan in the contract document.


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8. DISCOUNTS

Supplier shall not indicate any discount separately and quoted price should be after deducting

the discount.

9. MODE OF PAYMENT

9.1. In case of indigenous suppliers, all the payments due to Supplier shall be made in Indian

currency by crossed “Account Payee” cheque sent to the registered office of the Supplier.

Supplier can submit the banker details and payments can also be made through Electronic

Clearance System (ECS).

9.2. In case foreign suppliers LC will be established for supply portion and erection &

commissioning portion separately. The agency commission shall be paid in Indian Rupee based

on the suppliers authorization. Any other mode of payment shall be stipulated by the tenderer

clearly in the deviation statement attached in section-2A Annexure - II of the proposal

document.

10. TERMS OF PAYMENTS

General guideline TERMS OF PAYMENTS are as indicted below. Any deviation to these

payment terms to be brought out

10.1. 30 % of supply cost as an advance against submission of bank guarantee for an equal amount

from a reputed international/nationalized/scheduled bank and shall be valid till Contract

completion period. A format of Bank guarantee form shall be obtained from Department.

10.2. 60% of supply cost as milestone payment against factory inspection and receipt at site or LC

payment against dispatch in case of foreign supply

10.3. 10% of supply cost, Transportation charges and Commissioning & Erection charges after

successful commissioning & acceptance by purchaser and system covered under scope of

contract and against submission of Performance bank guarantee of 10% of contract value with

validity till warranty period.


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11. DELIVERY SCHEDULE

11.1. Supplier shall follow the following schedule for executing the contract

S. No Mile Stone Expected date of completion

T1 Letter of Intent / Purchase order date T

T2 Submission of Configuration and G.A.

Drawings

T1+ 4 weeks

T3 Date of clearance of Configuration and G.A.

Drawings

T2+ 2 weeks

T4 Submission of final drawings T3 + 1 weeks

T5 Submission of fully configured Automation

system for all the three machines for pre

delivery inspection at party’s site

T4 + 8 weeks

T6 Installation , Code Development, Testing &

Commissioning

T5 + 10 weeks

11.2. The Supplier shall inform the Purchaser within 30 days of any occurrence that is likely to cause

delay in delivery. The Purchaser shall determine, in the light of circumstances reported, whether

or not any respite or modification of the delivery requirements of the contract can be permitted

on this account.

11.3. An extension of the time limit for execution or postponement of delivery shall be granted only

in the respect of delay, which is not attributable to the fault or the negligence of the Supplier. An

extension of the time limit for execution shall be granted to the supplier to the extent that he

establishes force majeure events or that any action or inaction on the part of the Purchaser

makes the execution of the Contract impossible within the limit specified thereon. In other case

and with due regard to the justification provided, the Purchaser may grant respites.

12. LIQUIDATED DAMAGES

In the event of the Supplier failing to complete the work within the delivery period specified in

the contract agreement or any extension agreed thereto, the Purchaser shall reserve the right to

recover from the Supplier as liquidated damages, a sum of 0.5 percentage per week or part


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thereof of the undelivered portion of the total contract price of equipment or work. The Total

liquidated damages shall not exceed the 10.0 percentage of the total Contract price.

13. EXTENSION OF TIME

13.1. If the completion of deliveries of equipment, work is delayed due to reason of Force Majeure the

Supplier shall without delay give notice to the Purchaser in writing of their claim for an

extension of time. The Purchaser on receipt of such notice may agree to extend the Contract

period or delivery date as may be reasonable but without prejudice to other terms and conditions

of the Contract.

13.2. Both parties shall keep a record of the circumstances referred to above which are responsible for

causing delays in the execution of the services and shall give notice to the other party of any

such cause as soon as it occurs. An event of Force Majeure, where so ever it occurs, provided it

affects either party in fulfilling its obligations under this contract, shall justify the affected

party's claim of Force Majeure. Should one or both the parties be prevented from fulfilling their

contractual obligations by a state of Force Majeure lasting continuously for more than a month,

the parties shall consult with each other regarding the future execution of the contract.

14. FOREIGN EXCHANGE OUTGO AND VARIATION

14.1. Supplier shall indicate the Foreign exchange component considered in their offer. The foreign

exchange component shall be included in the lump sum price quoted / unit rates quoted. The

foreign exchange component shall be limited to the amount indicated.

14.2. For variation in foreign exchange rate for currency other than those indicated, the Base

Exchange rate for such currency prevailing on the date of price bid / revised offer whichever is

later subject to documentary evidence shall be considered.

15. TAXES AND DUTIES

15.1. EXCISE DUTY

SDSC-SHAR is eligible for Excise Duty Exemption under Notification No. 64/95 dated

16.03.1995 as amended by Notification No. 15/2007 dated 01.03.2007 and we shall provide

necessary Exemption Certificate. Wherever applicable, no claim for payment of Excise Duty or

Cenvat reversal will be allowed later. The supplier has to take this into account while

submitting quotations.

15.2. SALES TAX / VAT

With effect from 01.04.2007, the facility of Inter-State purchases by Government Purchasers

against Form-D has been withdrawn. Now the rate of CST on the Inter-State sale to


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Government Purchasers shall be the rate of VAT / State Sales Tax applicable in the State of the

selling dealer. Accordingly, the suppliers have to clearly indicate the %age of CST / VAT

applicable, against each case in their tenders.

15.3. SERVICE TAX

Service tax, if applicable, shall not be included but indicated separately in schedule of prices

(percentage of service tax applicable & amount on which it is applicable.

15.4. CUSTOMS DUTY

15.4.1 SDSC-SHAR is eligible for 100% Customs Duty exemption as per Notification

No.12/2012 dated 17.03.2012. This may be taken into account while considering the

import of items.

15.4.2 The customs duty that becomes payable even against production of customs duty

exemption certificate (limiting to the items as per the foreign exchange component

indicated in the price schedule) will be reimbursed on production of documentary

evidence ( copy of assessed Bill of Entry & TR-6 (challan)). Hence this component need

not be included in the quoted price.

15.4.3 Customs clearance and other formalities at the port of entry within the country shall be

handled by the Supplier at his own cost. Further the transportation from the port to the

work of Supplier or site shall be arranged by Supplier at his own cost.

15.5. INCOME TAX

Income tax at the prevailing rate as applicable and if applicable from time to time shall be

deducted from the supplier's bills as per Income Tax Act and a certificate issued (TDS

Certificate).

15.6. Earnest Money Deposit (EMD)

The Earnest Money Deposit(EMD) of Rs100000/- (Rupees One Lakh Only), refundable

(Without interest), should be necessarily accompanied with the Technical Bid of the agency in

the form of Demand Draft/Pay Order/Banker's Cheque drawn in favour of Accounts Officer,

SDSC SHAR , Sriharikota failing which the tender shall be rejected summarily.

The DD/PO/BC towards EMD shall be enclosed along with Technical Bid. in case, if it is

enclosed with Price Bid, the offer will not be considered.

The EMD in respect of the agencies which do not qualify the Technical Bid (First

Stage)/Financial Bid (Second competitive stage) shall be returned to them without any interest.

However, the EMD in respect of the successful tenderer shall be adjusted towards the Security

Deposit.


22

16. SECURITY DEPOSIT

16.1. The supplier whose tender is accepted will be required to furnish by way of Security Deposit for

the due fulfillment of the contract such a sum as will amount to 10 % of the contract price of the

work awarded in the form of Bank Guarantee valid till the satisfactory execution of the contract

and acceptance.

16.2. The security deposit (bearing no interest) shall be held by the Purchaser as security till

satisfactory competition, testing and handing over of all the system and for the due performance

of all suppliers’ obligations under the contract as per delivery period or extension granted

thereof by the Purchaser.

16.3. Within 10 days from the date of receipt of Letter of Intent, supplier shall deposit the security

deposit to the Accounts officer, Satish Dhawan Space Centre SHAR, Sriharikota as detailed

above by any of the following modes.

(a) By a crossed demand draft in favor of Accounts officer, Satish Dhawan Space Centre

SHAR drawn on SBI and payable at Sriharikota.

(b) By an acceptance bank guarantee. The bank guarantee shall be from a reputed

international/nationalized/schedule bank.

16.4. In case of breach of contract, the Security deposit shall stand forfeited in addition to other relief

available to the Purchaser under this contract.

17. PACKING AND FORWARDING

17.1. The Supplier shall arrange to have all the material suitably packed as per the standards &

statutes and as specified in the contract. Unless otherwise provided for in the contract, all

containers (including packing cases, boxes, tins, drums, and wrappings) used by the Supplier

shall be non-returnable.

17.2. All packing and transport charges, transit handling costs, transit risk coverage and transport fees

of agents employed at the place of delivery or elsewhere, shall be deemed included in the price

to be paid to the Supplier.

18. WARRANTY

The supplier shall provide twelve months warranty for the entire system for a defect liability,

after final official handing over at his cost. During this period supplier has to provide and

adhere to the following:

18.1. This period shall include maintenance; replacement of defective/failed parts at free of cost.

18.2. Supplier has to attend unlimited breakdown calls.

18.3. Purchaser will not provide any transport/accommodation for this purpose.


23

18.4. Upon oral or written notification of defects in or malfunctioning of the goods during the

warranty period which require corrective action, Supplier shall send the necessary personnel to

job site to supervise and assume responsibility for repairs and/or replacement, if necessary, of

the defective goods or material at his own cost. If Supplier does not, within seven (7) days after

receipt of notification, take steps to correct the breach, Purchaser may do so at the cost and

expense of Supplier. Supplier shall reimburse Purchaser all expenses incurred by Purchaser to

repair or replace malfunctioning or non-conforming goods.

18.5. Purchaser has no obligation to discover defects, patent or otherwise, and this shall be sole

responsibility of Supplier. Inspection and clearance for shipment by Purchaser’s inspectors or

Inspection agency appointed by Purchaser shall not relieve Supplier of any of his obligation and

duties under the terms and conditions herein.

18.6. Where defects in items are remedied under warranty, the period for which the warranty operates

shall be extended by such period, as the items were not available to the Purchaser. Where

defects items are replaced by new ones, the full warranty period stipulated in the contract shall

apply to such replacement items as from the date of their delivery.

18.7. Supplier shall obtain similar warrantee from each of his sub-suppliers. However, the overall

responsibility shall lie within the Supplier.

19. GUARANTEES:

The Supplier shall guarantee that the equipment furnished by him are in conformance with the

requirement of the specifications.

Goods covered by the contract shall be free from defects in design, materials or workmanship

for a period of twelve months from the date of successful commissioning & acceptance by

Purchaser.

20. PERFORMANCE BANK GUARANTEE

The supplier shall guarantee for the performance of the contract by providing bank guarantee

in favour of the Purchaser for an amount equivalent to 10 %( ten percent) of the total

value of this contract valid till the warranty period of the contract. The performance bank

guarantee shall be submitted by the supplier with in fifteen days from the date of accepting the

equipment as per the CONTRACT. The format for the performance bank guarantee shall be

obtained from Purchaser.

21. ARBITRATION

In the event of any question, dispute or difference arising under these conditions of any

condition in the purchase order or in connection with this contract, (except as to any matters the


24

decision of which is specially provided for by these conditions) the same shall be referred to the

sole arbitration of the Head of the Purchase office or of some other person appointed by him.

The arbitration shall be conducted with in India as per Arbitration & Conciliation Act 1996 and

the applicable language shall be English. The arbitrator may be a Retired Judge or a

Government Servant or any other responsible person, that he had to deal with matter to which

the contract is related or that in the course of his duties, he has expressed views on all or any of

the matters in dispute or differences. The award of the Arbitrator shall be final and binding on

the parties of this contract.

22. APPLICABLE LAW AND JURISDICTION

The laws of India shall govern this contract for the time being in force. The Courts of Andhra

Pradesh, India only shall have jurisdiction to be with and decide any legal matters or disputes

what so ever arising out of the contract.

23. FORCE MAJEURE

Should a part or whole work covered under this agreement be delayed due to reasons of Force

Majeure which shall include legal lockouts, strikes, riots, civil commotion, fire accident,

quarantines, epidemic, acts of God and Government, embargoes, the completion period for

work, equipment referred to in this agreement shall be extended by a period not in excess of

the duration of such Force Majeure. The occurrence shall be notified by either party within

reasonable time.

24. GENERAL

24.1. SITE DETAIL

26.1.1 The indented Automation Systems are to be erected inside a facility in SDSC SHAR,

Sriharikota, Nellore District, Andhrapradesh. The place”Sriharikota” is 20 km East of

Sullurupeta (nearest town) which is 80 km North of Chennai, Tamilnadu, INDIA.

26.1.2 SDSC SHAR, Sriharikota is prohibited place .Hence, no contractor, working personnel

will be allowed to stay and they have to be accommodated in Sullurupeta by his own

arrangement.

26.1.3 The contractor may have to transport working personnel on day to day basis by his own

arrangement. Location of the site is worked out to be 23 km from Sullurupeta.

26.1.4 The contractor personnel has to undergo security checks by security force i.e. CISF

26.1.5 All the working personnel shall comply with code of conduct during there stay inside the

SHAR campus.


25

24.2. SAFETY

Supplier shall follow the safety regulations / codes or safety instructions issued by

PURCHASER and shall take necessary measures at his own cost.

24.3. POWER SUPPLY

Electrical power provided by the purchaser during installation of Automation System is NOT

chargeable subjected to availability & approval. Reasonable quality of normal power will be

made available at one point (415V, 3 phase, 50 Hz). However, onward distribution shall be

done by the supplier.

All electrical installation by the supplier shall be as per safety regulation & standard and will

be subjected to purchaser inspection & approval.

24.4. CHANGES AND MODIFICATION TO SPECIFICATIONS, DESIGNS, DRAWINGS AND

QUALITATIVE / QUANTITATIVE REQUIREMENTS.

• Supplier shall obtain approval for the designs and drawings from the Purchaser before

initiating the action for procurement / fabrication.

• Change in make/model for bought item is NOT allowed unless approved by purchaser.

• Purchaser is free to modify the designs or drawings during design review. Party has to

carry out one time modifications at each stage without any extra cost and obtains the

approval from Purchaser. Two levels of design reviews are contemplated viz.

preliminary design review and detailed design review to meet overall specification of

the machine & sub system.

• The Purchaser reserves the right at any time to modify the Quantitative Requirement,

Specifications, patterns or drawings relating to the work covered by the contract. The

Supplier shall inform the Purchaser, within 15 days, of any objection/reservation to the

modifications required.

• Unless the Purchaser directs otherwise, the Supplier shall in either case, submit within a

reasonable time limit to be specified by the Purchaser, an estimate of the effect of any

such modification in the cost of performance of the contract and/ or on the delivery

schedule.

24.5. Any amendment to the contract, which may be necessary in this respect, will be established

within a reasonable time in the form of an Amendment to Contract to be signed by both

parties.


26

SECTION -2

SCOPE OF WORK


27

1. SUPPLIER’S SCOPE OF WORK

Purchaser contemplates execution of the works for the following.

1 DETAILED ENGINEERING, SUPPLY, ERECTION, TESTING AND

COMMISSIONING OF CONTROL & DATA ACQUISITION FOR BLAST CLEANING, DEGREASING AND RESIN LINING MACHINES AS PER DRAWINGS AND TECHNICAL SPECIFICATION DOCUMENTS.

01 no.

1.1. The scope of the work is not limited to the above but also includes all the requirements for the full

functionality of the system to meet all the requirements regardless of whether they are explicitly

mentioned or not.

1.2. The supplier shall be given pre-defined time to complete the action points raised during various

reviews such as design review, configuration drawings, etc. The action points have to be closed

within the given time. Otherwise it is considered as delay from supplier side and time will be

considered to impose LD.


28

SECTION -2A

ANNEXURE


29

Annexure –I

SCHEDULE OF PRICES

Note: This annexure shall be supplied along with upriced techno-commercial bid (without mentioning prices) and along with priced bid separately (with prices mentioned).

S. No Description Unit

Cost

(in Rs/foreign currency as applicable.)

1.

Supply of all Instrumentation and Control System as described in Section 3 and Annexure- 1 & 2 which includes Instrumentation systems covering proximity sensors, absolute encoders etc. & PLC based control system consisting of all controls from MMIs, Interlocks, cables, PLC Panel & Operator Panel & associated accessories, UPS etc. and SCADA system for Grit Blast Cleaning, Degreasing and Resin Lining systems.

Lump sum

2.

Installation, Configuration, Programming, Testing, Erection and Commissioning of the Automation system (including PLC and SCADA system as described in Section-3) for Grit Blast Cleaning, Degreasing and Resin Lining Machines.

Lump sum

3. VAT/CST on items in S.No.1 %

4. Transportation Charges of S.No. 1 Lump sum

5. Service Tax on Item in of S.No. 2 %

6. TOTAL COST(1+2+3+4+5)

(SIGNATURE OF SUPPLIER)


30

Annexure-II

EXCEPTIONS AND DEVIATIONS (FORM-J)

Tenderer shall submit the following information along with the unpriced techno-commercial bid.

In line with Proposal Document, supplier may stipulate Exceptions and deviations to the Proposal conditions if considered unavoidable.

SL.NO

Reference in Specification

Dept. Spécification

Offered

Spécification DEVIATION

PAGE

NO CLAUSE

NO

NOTE :

Only deviations are to be written in this FORM-J.

Any deviations taken by the Bidder to the stipulations of the Proposal document shall be brought out strictly as per this format and enclosed along with the bid.

Any deviations not brought out as per this Proforma (FORM-J) and written elsewhere in the Proposal document shall not be recognized and the same is treated as null and void.

Any willful attempt by the Tenderer to camouflage the deviations by giving them in the covering letter or in any other documents that are enclosed may render the Bid itself non-responsive.

(SIGNATURE OF SUPPLIER)


31

Annexure -III

CHECK LIST


S. No Description Response by Supplier

1. The detailed scope of work and technical specifications are under stood and price was quoted accordingly

Yes / No

2. All the general conditions of the contract as per the section-1are acceptable.

Yes / No

3. In case of some general conditions of the contract as per the section-1 are not acceptable, deviation statement is to be enclosed as per Annexure-II in section 2A

Yes / No

4. The supplier evaluation format as enclosed along the proposal document is filled-in and necessary supporting documents are enclosed.

Yes / No

5. Compliance statement as per section 2A-Annexure-IV has been filled.

Yes / No

6. Un-priced copy of schedule of prices, payment schedule is enclosed in the techno-commercial bid.

Yes / No

7. Taxes are quoted in the price bid Yes / No

8. List of essential spares and material are enclosed to the priced bid with unit rate

Yes / No

9. Delivery schedule is acceptable. If not, the deviation is brought-out in the deviation statement Annexure-II in section 2A

Yes / No

10. Terms of payment are acceptable. If not, the deviation is brought-out in the deviation statement Annexure-II in section 2A

Yes / No

11. Liquidate damages clause is acceptable. If not, the deviation is brought-out in the deviation statement Annexure-II in section 2A

Yes / No

Signature of Supplier with Seal


32

COMPLIANCE STATEMENT - INSTRUMENTATION AND DATA ACQ UISITION SYSTEM


Sl. No.

DESCRIPTION AGREE DISAGREE REMARKS

1.

Supply (as per the specifications given), Installation, Testing, Programming and Commissioning of all Instrumentation and Control System shall be done by an authorized Siemens system integrator. Mention the SIEMENS authorized system integrator name and details.

2. PLC based Data Acquisition and Control System (DACS) shall be designed as per the drawings, specifications & Inputs list.

3. SCADA Architecture, specifications of MMI, SCADA screens, reports, trends etc. shall be submitted for approval at each stage of development.

4.

All Drawings & datasheets pertaining to PLC, Ethernet switches, cables, Field instruments and panels etc., shall be submitted for approval prior to procurement.

5.

Programmable Logic Controller (CPU, Interface modules, Power modules & Input modules) shall be supplied as per the specifications given in section3-Annexure2.

6. All the Panels shall be supplied as per the specifications given in section3-Annexure2

7.

230V AC UPS system with parallel redundant configuration shall be supplied as per specifications provided in Annexure along with necessary test reports.

8. DC power supply shall be supplied as per the specifications given in Annexure along with necessary test reports.

9.

All the field instruments shall be supplied as per the datasheets (refer section3-Annexure2) & with the necessary fittings for installation, testing & commissioning along with necessary test reports.


33

Signature of Supplier with Seal

10. Network Switches shall be supplied as per the specifications given in section3-Annexure2 along with necessary test reports.

11. Signal cables & Control cables shall be supplied as per the specifications given in section3-Annexure2 along with necessary test reports.

12. Installation, Commissioning and testing of all the three systems as per the specifications mentioned in the indent.

13.

Program development for PLC as well as SCADA must be done at site in consultation with Department. DAS programming shall be as per IEEE 12207 standard.

14. Software developed shall incorporate all the specified interlocks. The software shall be developed in compliance with the software standards mentioned.

15.

All the items will be inspected at factory before dispatch by SHAR. Factory Acceptance Test (FAT) procedure shall be submitted for the approval prior to inspection.

16.

After delivery of items to site & completion of installations, Site Acceptance Test at SPP, SHAR will be carried out. Site Acceptance Test (SAT) procedure shall be submitted for the approval prior to inspection.

17.

In case of any deviations from the given specifications, the same shall be submitted to SHAR in detailed tabular format with the proper justifications.


34

SECTION -3

Technical Specifications of Instrumentation & Control System Requirements for Grit Blast Cleaning, Degreasing and Resin Lining processes of PSOM -XL & S139

segments at SPP


35

Contents

I. Introduction ........................................................................................................ 37

II. General Scope ..................................................................................................... 39

1. Scope of Supplier ........................................................................................... 39

2. SCADA System .............................................................................................. 40

III. Working, Operational Sequence, Control Philosophy and Interlocks ............ 43

1. Grit Blasting System ...................................................................................... 43

A. Working of Blast Cleaning Machine: ........................................................ 43

B. Operational sequence: ................................................................................ 43

C. Interlocks .................................................................................................... 44

2. Degreasing System ......................................................................................... 46

A. Working of Degreasing Machine: .............................................................. 46


C. Interlocks .................................................................................................... 47

3. Resin Lining System ...................................................................................... 49

A. Working of Resin Lining Machine: ........................................................... 49


C. Interlocks .................................................................................................... 50

IV. Codes and Standards ......................................................................................... 51

V. I & C System Configuration, Panels and Other Details .................................. 53

1. I&C Configuration ........................................................................................ 53

2. Operator Panel and other subsystems .......................................................... 54

3. I&C Cables..................................................................................................... 55

4. Cable Glands .................................................................................................. 55

5. Cable trays ..................................................................................................... 55

6. Wiring ............................................................................................................ 56

7. Cable Terminations ....................................................................................... 56

8. Plug Points and Interior Lighting ................................................................. 56

9. Relays ............................................................................................................. 56


36

10. Isolator ........................................................................................................... 56

11. Labels ............................................................................................................. 57

12. Earthing ......................................................................................................... 57

13. System Grounding ......................................................................................... 57

14. I/O Count ....................................................................................................... 57

15. Drawings .................................................................................................... 58

16. Technical Specifications ........................................................................ 58

VI. Documents to be produced on acceptance of Purchase Order before start of fabrication. ................................................................................................................. 59

VII. Scope of Inspection, Testing and Acceptance ................................................... 60

1. Inspection,Testing &Acceptance of Instrumentation & Control System .. 60

A. General ........................................................................................................ 60

B. Factory Acceptance Tests (FAT) ............................................................... 60

C. Site Acceptance Tests (SAT) ...................................................................... 61

D. Instrument Calibration. ............................................................................. 62

E. System Validation ....................................................................................... 62

F. Final Operational Testing and Acceptance. .............................................. 63

2. Commissioning,Trials,Final Acceptance and Training at SDSC,SHAR. ... 63

3. Scope of Supplier includes the supply of following Items: .......................... 64

4. Terms and Conditions ................................................................................... 64

VIII. Annexures ...................................................................................................... 66

1. Drawings ........................................................................................................ 66

Technical Specifications ......................................................................................... 72


37

Technical Specifications

I. Introduction

Indian Space Research Organisation (ISRO) is planning to set up a new Hardware Insulation Lining facility at Solid Propellant Plant (SPP) in Sriharikota Range (SHAR) for manufacturing S139 and PSOM-XL motors required for PSLV and GSLV Launch Vehicles. Each of these motors consists of solid propellant processed in 3 types of segments, viz., head end segment, middle segment and nozzle end segment. Hardware Insulation Lining Facility is primarily meant for hardware surface cleaning, insulation lining and resin lining before being sent for further processing.

The segment hardware is received duly assembled with end rings from ISRO work centre in this

facility. Preliminary cleaning, dimensional and visual inspection is carried out. The inside surface of the hardware is cleaned thoroughly with grit blasting followed by degreasing with solvent. Both these operations are carried out in horizontal position by keeping the hardware on roller stands. This cleaned surface is lined with rubber sheets (insulation) to protect hardware thermally during launching. The hardware is then kept in autoclave for proper vulcanisation of the insulation. After vulcanisation, the hardware is tilted to vertical position from horizontal position and insulation lining is machined to achieve tongue and groove joint by using CNC machine. Hardware is again tilted back to horizontal position and resin lining is applied. This resin lining functions as bonding agent between propellant and insulation. Hardware is sent to casting facility after carrying out of final inspection of resin lining.

Grit blast cleaning system is intended to impart Sa 2 ½ surface finish as per SIS-05-5900 to inner surface of hollow steel cylindrical chambers (segment) of different diameters and lengths. Inner surfaces are blast cleaned to remove mill scale and to prepare a clean surface for rubber lining. Blast cleaning operation shall be carried out by using iron grits. Degreasing is carried out to remove dust and clean the inner surface of hardware. It involves degreasing with Trichloroethylene solvent followed by recovery of solvent by evaporative distillation. Resin lining system is used in order to provide a thin layer of resin liner on rubber lined surface to facilitate proper bonding between insulation and propellant.

This document details the design and plan for automation of three basic stand alone machines for hardware preparation of PSOM-XL at new Hardware Insulation and Lining building at SPP viz.: Grit Blast Cleaning System, Degreasing System and Resin Lining System. The three machines will be linked to a centralized Data Acquisition and Control System.


38

Blasting Cleaning System:

Grit blasting is carried out to remove paint and scale on the inner surface of the hardware and impart roughness to the surface. It involves girt blasting of hardware inner surface with chilled iron grits at 5 bar delivery pressure.

Blast cleaning system consists of blast generator, grit conveyor with bucket elevator for grit recycling, dust extractor with shaker motor, safety devices, control panel, roller stand boom and lance mechanism, electrical works and Instrumentation & Controls for all of the above. Blasting operation is carried out through the blast generator, using the fine iron grit, along with the mixing chamber provided at the bottom of blast generator. Grit that passes through Blast generator will flow with 5 bar air pressure and will be controlled by 2 solenoid valves. One is for air flow control and other one for iron grit flow control. Blast generator is having 2 chambers: upper chamber and lower chamber. The selection of the chamber is done by solenoid valve. If solenoid valve is OFF, upper chamber will run, if solenoid valve is ON, lower chamber will run This will ensure uniform iron grit flow to the mixing chamber wherein air and iron grit will be combined and passed through the hose to the blasting nozzle.

Degreasing System:

Degreasing is carried out to remove dust and clean the inner surface of hardware. It involves application of Trichloroethylene solvent to the hardware surface followed by recovery of solvent by evaporative distillation.

Degreasing operation will be carried out through the spray pump with TCE. TCE will be sprayed with 3 bar pressure on the surface of rotating hardware. TCE pressure is monitored while spraying operation. Separate subsystems are used to storage and maintain TCE. Storage and distillation tanks are provided with level switches, temperature switches, pressure gauges and heating coil arrangements. After cleaning the hardware surface, used TCE is collected in the distillation tank. Through distillation process clean TCE will be regenerated and is collected in storage tank.

Resin lining System:

Resin lining process is carried to apply a thin layer of resin liner on rubber lined surface to facilitate proper bonding between insulation and propellant. In this system, resin will be sprayed on surface of segments by a positive displacement pump through a spray nozzle along with 3 bar nitrogen pressure. Pump will be driven by variable frequency drive (VFD). Depending up on the location of the segment different frequencies were selected by PLC in VFD, as per program sequence.


39

II. General Scope

This section covers the general requirements for supply of materials, preparation of detailed drawings, manufacture, testing & inspection of contractor’s works, packing, forwarding, transportation, transit insurance, unloading at site, erection, testing & commissioning of Data Acquisition and Control system for the Hardware Insulation and Lining facility at SPP as per specifications in this section, enclosed data sheets, drawings & other documents

1. Scope of Supplier

i. Supply, erection and commissioning of Automation & Control systems as per the specifications given in this document for Grit Blast Cleaning, Degreasing and Resin lining systems.

ii. Supply, erection and commissioning one no. of completely wired Control Panel each for Blast Cleaning, Degreasing and Resin Lining systems as per the G.A drawings approved by Department. Control Panel for all the three systems shall be PLC (Programmable Logic Controller) based. The Control Panel shall be fully wired with Isolators /multipliers, Relays,MIL-26482 qualified circular multi-pin connectors etc. The Control Panel shall be located inside the Room, away from the machines.

iii. Two local modular operator panels (One which is common to blast cleaning and degreasing

systems and another one for resin lining system) shall also be commissioned for Control & Monitoring of the various operations in the three machines as per the G.A drawings approved by Department. The Operator panel should house only MMIs. Communication between PLC’s in PLC panels and MMIs in operator panels shall be through Ethernet protocol.

iv. Supply, erection & commissioning of Proximity Sensors, Encoders and other instruments required for all the three machines. (Detailed specifications have been given in Annexure).

v. All erection hardware for field instruments installation. Cable Trays & GI conduits from field instruments to Control Panels. Earthing for all field instruments Control Panels and Operator Panels shall be as per scheme shown in drawing– Grounding Scheme. Complete loop checking of all I/O chains shall be done by Contractor. The Contractor’s scope of work shall include trial runs, start up, commissioning and process trials of systems covered in this specification. All instruments required for reliable & safe operation of the all the three machines and their subsystems shall be provided by the system vendor.

vi. The scope of work also includes interfacing with equipments such as VFDs, IMCCs from

electrical panel (SIMOCODE) to display various electrical parameters and diagnostic parameters in SCADA. Wiring works, which includes laying cable (copper as well as PROFIBUS), crimping, ferruling as per standard pattern till TBs in electrical panel is also under the scope of supplier.

vii. Program development for PLC as well as SCADA must be done at site in consultation with

Department. DACS programming shall be as per IEEE 12207 standard. Detailed User


40

requirements will be provided after award of the contract. The list of software licenses and specifications of the DACS PCs must be approved by Department before procurement.

viii. Party shall submit project execution plan along with their offer, detailing the methodology of

contract execution. ix. Details of documents to be produced by party at various stages are detailed in subsection VI.

The necessary installation drawings to be submitted for approval by SHAR by 4 weeks from the date of award of Purchase order. All the three systems to be erected, and commissioned, completion of Performance demonstration by 18 Weeks from the date of Clearance of Design and Drawings

x. Factory Acceptance tests (FAT) & Site Acceptance tests (SAT) to meet the design

specifications & functional requirements. Scope of inspection, testing requirements and acceptance are detailed in subsection VII.

xi. Contractor shall provide soft copy (2 nos.) and hard copy (2 nos.) of the catalogues, and manuals of all the components and systems and as built circuit diagrams.

xii. All the Instrumentation & Control subsystems need to be transported to SHAR by the supplier

and Unloading at our site by supplier using their own resources and expense.

xiii. Erection of all the above subsystems at “Hardware Preparation Facility” at SPP, SDSC SHAR.

xiv. Commissioning, Trials, Final Acceptance, Demonstration of the working of System for its satisfactory performance. Performance of this machine to be proven by trials by the party for its acceptance at SHAR and Training at SHAR as detailed in Section VII-2.

xv. All the terms & conditions described in subsection VII-4 shall be satisfied.

xvi. Training for six SHAR engineers shall be arranged on the DACS system from Original Equipment manufacturer (Siemens) for minimum of 7 days by the vendor.

xvii. The party shall necessarily submit the filled compliance statement.

2. SCADA System

i. A Supervisory Control and Data Acquisition System must be realized in HIL which will enable the user to control, acquire as well as log all the data from the hardware preparation processes.

ii. Configuration of the SCADA system for the new facility is as given below:

Each of the three PLCs will be connected to separate standalone SCADA system. Simultaneously, all the three PLCs will be connected to one backup SCADA systems also. Three SCADA clients will be connected from these backup SCADAs for operation purpose alone. Detailed overall schematic has been given in the drawings section. (Refer Page Nos. 68,70,71).


41

iii. The party will be responsible for realizing the communication among all the three standalone

PLCs, MMIs, clients and other field devices (VFDs, Weighing System, IMCC etc.) which include laying communication cable, configuration development, commissioning, testing and report generation regarding the same.

iv. SCADA developed for the HIL system must have the following features: a. Dynamically configurable Mimics, b. Real time & Historical data trends, c. Data logging & Report generation in user prescribed format, d. Tags (PLC & Third party tags). e. Alarms & Events Logging. f. Access security management.

v. Mimics

a. MMI-PLC-IO network configuration screen with critical diagnostic information and messages.

b. Sub-system wise screens to monitor the process status. c. Sub-system wise I/O screen.

vi. Trends

a. Real time & historical trends. b. X- axis & Y- axis ranges shall be user selectable. c. Trend configuration shall be user-friendly & shall be available during Run-time. d. Trends data export to MS Excel (.xls) format shall be provided. e. Print option for trend chart shall be provided. f. Trend analysis tool shall be provided as per the user requirement.

vii. Data Logging

a. Time based (with minimum 1sec interval) & Event based data logging for all inputs shall be provided.

viii. Events and Alarm Logging a. Alarms & Events shall be logged separately. b. Sub-system wise filtration option. c. Logging shall be as per user defined format.

ix. Report Generation a. Reports shall be generated for logged data, alarms & events as per the user defined

formats. b. From- & To- date and time shall be user selectable. c. Time interval shall be user selectable. d. Options to export data in MS Excel, MS Access, SQL formats. e. Print report option shall be provided.

x. Access Security Management


42

a. Access to SCADA operations will be allowed only after authentication. Different user levels and access levels will be intimated during detailed engineering.

xi. License

a. Standalone Run time SCADA with 300tags (for MMIs directly connected to PLC) : 3 Nos.

b. Standalone Configuration SCADA with 900 tags (Backup MMI- Engineering Station where data logging is done) : 1 Nos.

c. Runtime Clients (which will be connected to backup MMI through Ethernet switch) : 3 Nos.

xii. Make : GE iFix5.8 or latest version/Siemens WinCC

xiii. 1 no. of Colour laser Printer also to be supplied.


43

i. III. Working, Operational Sequence, Control Philosophy and

Interlocks

1. Grit Blasting System

A. Working of Blast Cleaning Machine: i. Hardware extension is attached to the end ring at fore end of the segment. Other end of

segment shall be closed by an “End Cover.

ii. Rocket Hardwares are cylindrical chambers of diameter 1000mm&2800mm assembled with end rings of Diameter 1380mm& 3320mm for PSOMXL and S139 and respectively. The length of PSOMXL segment &S139 segment is 4650mm &3800mm (approx) respectively. At the time of blast cleaning either PSOMXL orS139 Hardware is placed on the roller Stand and rotated at 1rpm to 3 rpm speed. At this condition free end of hardware extension is projected inside the blast cabinet.

iii. Boom is supported on guide rollers in Boom Support Structure. The boom is powered by motor and chain drive to move in the rectilinear direction along the axis of the segment.

iv. While boom carrying the Lance & blasting nozzle assembly moves axially into the segment, the segment rotates in-order to Blast clean the entire inner surface of the segment. Lance is indexed to position the gun in required orientation while blast cleaning of the curved surface at HES & NES Dome is carried out

v. The Blast generator mixes the grit with air and the grit is carried away with the compressed air through hose and comes out of the blast nozzle to strike against inner surface of the segment. The used grit will travel to the blast cabinet by gravity. This grit will be transported to the bucket elevator area by screw conveyer. Bucket elevator carries the grit to the top of the classifier unit. Classifier unit has Vibro-screen which segregates the very fine grit/powder and also big size paints scrap pieces from the useful grit. Useful grit is again feed back to the blast generator.

vi. The 6” diameter hose from the dust collection system of will run through the boom and face the blast cleaned surface to suck away the dust from the cleaned surface without allowing the dust to get settled.

vii. The mechanical shaker type dust collector will be provided to filter dust laden air through filter media. Dust collected on filter bags shall be removed by mechanical shaking of the bags. The efficiency of the dust collector shall be minimum 99 % down to 5 micron particle size.

B. Operational sequence:

i. Assemble the Hardware Extension to the segment fore End Ring and End cover with gasket on the segment rear end.

ii. Open the covers of the blasting cabinet


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iii. Load the segment assembled with Hardware extension and end cover on roller stand. In this

condition the hardware extension is projected inside the Blast Cabinet.

iv. Close the front covers of the blasting cabinet located at the Blast Cabinet-segment interface.

v. On the Operator panel, select the type of segment to be blast cleaned i.e. Head end or Middle or Nozzle end segment. This selection shall be done through MMI.

vi. Start / Stop for Motor with brake for hardware support roller stand drive and Motor with break for boom travel shall be from MMI.

vii. Speed of segment rotation and boom movement shall be controlled using Variable Frequency Drive. However, the VFD module must have an appropriate interface (PROFIBUS) to communicate with PLC. The speed of the boom as well as segment rotation is controlled.

viii. Initially, the dome section of the hardware (HE, NES) is to be blast cleaned in case of Head End Segment and Nozzle End Segment followed to cylindrical portion. Hence, the boom with lance positioned at 0° is to be taken inside the chamber up to the shell end. In this condition, by swiveling the lance (0°-45°) and moving the boom forward or backward, the required stand-off distance of 250-350mm between the tip of the nozzle and the surface of the hardware is to be achieved. After completing the dome section, keeping the lance at 45°, the boom is to be withdrawn through the chamber to complete blast cleaning of the cylindrical portion. Once the lance comes out of the cylindrical shell portion, the boom is to be taken up to the HOME position. Then the lance is to be swiveled to 135°in two stages, from 45-90° and 90-135° inside the cabinet .In this condition, the boom is to be moved forward in to the hardware and the nozzle is to be positioned in such a way to facilitate the blast cleaning at 45° tapered position of the segment adjacent to the machined assembly interface. After completing this, the boom is to be withdrawn to HOME position and machine is to be switched off.

ix. After the end of blast cleaning operation, segment is unloaded from roller stand. Front covers of the Blast Cabinet and the End cover (located on the End ring) are to be opened

C. Interlocks

i. The front covers located at the segment-cabinet interface and end cover has to be closed for the blasting operation to begin. (This has to be sensed by providing Proximity sensor)

ii. Linear movement of the boom and nozzle has to start only after the segment has started rotating.

iii. A program sheet with the details of movement of boom and lance with time will be supplied during program development. The encoder provided for the drives for longitudinal and swiveling motion shall be absolute type (non-incremental) with sufficient resolution to monitor as well as achieve the required movement i.e., the encoder must be mounted with positive coupling / transmission and measurement range of encoder must correspond to full


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range of boom travel and lance swiveling. PLC program must include diagnostic features of encoder also.

iv. Blasting command could not be issued when there is no segment rotation (unless specifically mentioned in the program sheet)

v. Suitable proximity switches shall be provided for segment identification as well as for travel limit identifications. The lengths of six segments namely, HE, MS, NES of S139 and PSOM XL are different and hence the travel limits for the six segments are different. The travel limits for the six cases have to be detected by suitable proximity switches, which must be in turn interlocked with the segment selection in MMI such that for the chosen segment, only the corresponding proximity switch activates to limit the travel appropriately. Interlocks must be incorporated in such a way that over travel of boom and lance are totally arrested.

vi. Separate provision must be incorporated in order to diagnose healthiness of VFD, IMCC, screw conveyor, bucket elevator, shaker, and classifier. VFD diagnostic messages must be transferred to PLC through PROFIBUS.

vii. Inlet pressure to blast generator must be monitored using pressure transmitter and blasting command should be issued only when the pressure is within set limits.

viii. Blast cleaning operation shall start only when screw conveyor, bucket elevator, dust collector and Vibro-screen are working.

ix. Interlock to prevent swiveling of lance from 50° to 135°orientation inside the segment.

x. The blast Cleaning operation shall stop under any of the following conditions: a. For all the hardware segments, if segment stops rotating. This shall be sensed by

detection of movement of the non-driven roller by proximity sensors.

b. For all the hardware segments, when the longitudinal travel of the Boom stops. (This shall be detected by encoder for longitudinal travel of the boom.)

c. For HE and NE hardware segment, the swivel motion of the Lance and longitudinal travel of the Boom stops. This shall be detected by the encoder for the lance for swiveling motion and by encoder provided for longitudinal movement of the boom.

xi. During the idle run of the Boom, the lance has to be located at 0°. This is to prevent the interference of the Lance either with the Blast Cabinet with the segment during loading / un-loading (if the lance is located at 90°).

xii. In addition to the above the party shall provide all necessary interlock for the safe and reliable operations of the machine during blast cleaning of the Hardware at the time of actual program development. The above mentioned list of interlocks is tentative. Final list of interlocks will be provided to the Contractor at the time of actual program development.


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2. Degreasing System

A. Working of Degreasing Machine: i. The Hardware extension is attached to the end ring at fore end of the segment. Other end of

segment shall be closed by an “End Cover. The diameter of end rings is 1380mm and 3320mm for PSOM-XL and S139 segment respectively. The lengths of the segments are 4650mm and 3780mm (approx) for PSOM-XL and S139 segment respectively. The Hardware assembled with end cover and Hardware extension is loaded on the rollers of roller stand and rotated at 1rpm to 3 rpm speed. At this condition free end of hardware extension is projected inside the degreasing cabinet.

ii. Boom is supported on guide rollers in Boom Support Structure. The boom is powered by motor and chain drive to move in the rectilinear direction along the axis of the segment.

iii. While boom carries the lance, the degreasing nozzle assembly moves axially into the segment. The segment rotates on the rollers at a defined speed so that the entire inner surface of the segment is solvent cleaned. For cleaning the domed regions of HE and NE segments of S139 and PSOM-XL the Lance with spray nozzle is indexed to the required position with respect to boom axis.

iv. The TCE circulation pump circulates the TCE from the TCE Storage Tank, through hose and TCE nozzle to spray on the inner surface of the segment. The used TCE is collected in to the Degreasing cabinet by gravity. This TCE Solvent will be pumped back to the Collection Tank by collection pump.

v. The exhaust hose for vapor evacuation sucks the TCE vapor from the Degreasing Cabinet and discharge outside of the building by an exhaust blower.

B. Operational sequence: i. Assemble the Hardware Extension to the segment fore End Ring. Assemble the End cover

with gasket on the segment rear end.

ii. Open the covers of the degreasing cabinet

iii. Load the segment with hardware extension and end cover on roller stand. In this condition the hardware extension is projected inside the Degreasing Cabinet.

iv. Close the front covers of the Degreasing cabinet located at the Degreasing Cabinet-segment interface.

v. On the operator panel, select the type of segment to be solvent cleaned i.e. Head end or Middle or Nozzle end segment of PSOM XL or S139 hardware. This selection shall be done through MMI.

vi. Start / Stop for motor with brake for Rollers stand drive and motor with brake for boom travel shall be from MMI.


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vii. Speed control of segment rotation and boom movement is by Variable Frequency Drive. However, the VFD module must have an appropriate interface (PROFIBUS) to communicate with PLC. The speed of the boom as well as segment rotation is controlled.

viii. Initially, the dome section of the hardware is to be solvent cleaned in case of HES &NES, following to cylindrical portion. Hence, the boom with lance positioned at 0° (with respected axis of the segment) is to be taken inside up to the shell end. In this condition, by swivelling the lance (0°-45°) and moving the boom forward or backward, the required stand-off distance of 250-350mm between the tip of the nozzle and the surface of the hardware is to be achieved. After completing the dome section, keeping the lance at 45°, the boom is to be withdrawn through the cabinet to complete solvent cleaning of the cylindrical portion. Once the lance comes out of the cylindrical shell portion, the boom is to be taken up to the HOME position. Then the lance is to be swivelled to 135°in two stages, from 45-90° and 90-135° inside the cabinet .In this condition, the boom is to be moved forward in to the hardware and the nozzle is to be positioned in such a way to facilitate the solvent cleaning of 45° tapered position of the segment adjacent to the machined assembly interface. After completing this, the boom is to be withdrawn to HOME position and machine is to be switched off.

ix. After solvent cleaning operation, front covers of the Degreasing Cabinet are to be opened and segment is unloaded from roller stand

C. Interlocks

i. The front covers located at the segment-cabinet interface and end cover have to be closed for commencing the degreasing operation to begin. (This has to be sensed by providing limit switch)

ii. The front covers located at the segment-cabinet interface and end cover are to be closed for commencing the degreasing operation to begin. (This has to be sensed by providing proximity switch)

iii. Linear movement of the boom and nozzle has to start only after the segment has started rotating. A program sheet with the details of movement of boom and lance with time will be supplied during program development. The encoder provided for the drives for longitudinal and swiveling motion shall be absolute type (non-incremental) with sufficient resolution to monitor as well as achieve the required movement i.e., the encoder must be mounted with positive coupling / transmission and measurement range of encoder must correspond to full range of boom travel and lance swiveling. PLC program must include diagnostic features of encoder also.

iv. Solvent Cleaning command could not be issued when there is no segment rotation (unless specifically mentioned in the program sheet)

v. Suitable proximity switches shall be provided for segment identification as well as for travel limit identifications. The lengths of six segments namely, HE, MS, NES of S139 and PSOM XL are different and hence the travel limits for the six segments are different. The travel limits for the six cases have to be detected by suitable proximity switches, which must be in turn interlocked with the segment selection in MMI such that for the chosen


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segment, only the corresponding proximity switch activates to limit the travel appropriately. Interlocks must be incorporated in such a way that over travel of boom and lance are totally arrested.

vi. Separate interlocks must be incorporated in order to ensure healthiness of VFD, IMCC and circulation pumps. VFD diagnostic messages must be transferred to PLC through PROFIBUS.

vii. Pressure in the solvent circulation hose to be monitored using pressure transmitter to ensure TCE spray.

viii. Solvent cleaning operation shall start only when boom and roller stand are “ON”.

ix. The lance shall be maneuverable from 0 to 50 degrees inside the case and also interlock to be provided to prevent the swiveling of lance from 50° to 135°orientation inside the segment.

x. The Solvent Cleaning operation shall stop under any of the following conditions: a. For all the hardwares if it stops rotating. This shall be sensed by detection of movement

of the non-driven roller by proximity sensors. b. For MS hardware segments, when the longitudinal travel of the Boom stops. (This shall

be detected by encoder for longitudinal travel of the boom.) c. For HE and NE hardware, the swivel motion of the Lance and longitudinal travel of the

Boom stops. This shall be detected by the encoder for the lance for swiveling motion and by encoder provided for longitudinal movement of the boom.

xi. During the idle run of the Boom, the lance has to be located at 0°. This is to prevent the

interference of the Lance either with the Degreasing Cabinet (if the lance is located at 135°) or with the segment during loading / unloading (if the lance is located at 90°).

xii. In addition to the above the party shall provide all necessary interlock for the safe and reliable operations of the machine during resin lining of the Hardware at the time of actual program development. The above mentioned list of interlocks is tentative. Final list of interlocks will be provided to the Contractor at the time of actual program development.


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3. Resin Lining System

A. Working of Resin Lining Machine: i. Cylindrical chambers of diameter 1000mm & 2800mm with end rings of Diameter

1380mm & 3320mm and length 4650mm & 3800mm (approx) is kept on rollers and rotated at 1rpm to 3 rpm speed. One hardware of either PSOMXL OR S139 is taken up for processing each time.

ii. Boom is supported on guide rollers in Boom Support Structure. The boom is powered by motor and chain drive to move in the rectilinear direction along the axis of the segment.

iii. While boom carrying the Lance & spray gun assembly moves axially into the segment, the segment rotates to synchronize with the linear movement of the boom in order to cover the entire inner surface of the segment with liner coating. Lance is Swiveled to position the gun in required orientation while liner spray on the curved surface is carried out(at HES & NES Dome)

iv. The Liner Pump discharges the Liner at controlled flow rate, through hose and spray gun to

spray the Liner on the insulated surface of the segment. The Liner Pump is controlled by Drive and the PLC.

v. Exhaust blowers suck the Liner vapor from the Resin Lining machine locality and discharge to out of the building by exhaust blower.

B. Operational sequence: .

i. Load the segment on the roller stand.

ii. On the Operator panel, select the type of segment to be Liner coated i.e. Head end or Middle or Nozzle end segment of PSOMXL or S139 Hardware. This selection shall be done through MMI

iii. Start / Stop for brake motor for hardware support roller drive and brake motor for boom travel shall be from MMI.

iv. For speed control of segment rotation and boom movement, VFD shall be used. However, the VFD module must have an appropriate interface (PROFIBUS) to communicate with PLC. The speed of the boom as well as segment rotation is controlled. The indexing of the lance also controlled by PLC.

v. Start the resin lining operation.

vi. Provision must be available to select one of the two resin pumps, from MMI.

vii. Operator must be able to operate all motors / Pump from MMI.


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viii. Liner Coating is carried out in both forward and reverse pass. At dome the curved surface is covered by swivelling the lance (0°-90° with respect to the axis of segment) and moving the boom forward or backward, to achieve the required stand-off distance of 250-350mm between the tip of the spray gun and the surface of the hardware. At shell area, keeping the lance at 90°, the boom is moved to and forth to complete the liner coating. Once the lance comes out of the cylindrical shell portion, the spray is stopped and boom is to be taken up to the HOME position.

ix. After completion of Liner Application, segment is to be unloaded from roller stand.

C. Interlocks

i. Linear movement of the spray gun (boom) has to start only after the segment has started rotating.

ii. Linear movement of the spray gun (boom) has to start only after the segment has started rotating.

iii. The swiveling motion of the nozzles will start only after the cylindrical part of the segment has been lined. (Proximity switches shall be provided that will indicate the end of cylindrical section for each segment.).

iv. A program sheet which details of movement of boom and lance with time will be supplied during program development.

v. Since the radius of the spherical part and the radius of the cylindrical part of the Head end segment are not the same, so longitudinal movement will have to be carried out simultaneously along with the swiveling movement of the Lance in order to position the spray gun within the stand-off distance.

vi. The encoder provided for the drives for longitudinal and swiveling motion shall be absolute type (non-incremental) with sufficient resolution to monitor as well as achieve the required movement i.e., the encoder must be mounted with positive coupling / transmission and measurement range of encoder must correspond to full range of boom travel and lance swiveling. PLC program must include diagnostic features of encoder also.

vii. Suitable proximity switches shall be provided for segment identification as well as for travel limit identifications. The lengths of six segments namely, HE, MS, NES of S139 and PSOM XL are different and hence the travel limits for the six segments are different. The travel limits for the six cases have to be detected by suitable proximity switches, which must be in turn interlocked with the segment selection in HMI such that for the chosen segment, only the corresponding proximity switch activates to limit the travel appropriately. Interlocks must be incorporated in such a way that over travel of boom and lance are totally arrested.

viii. Separate interlocks must be incorporated in order to diagnose healthiness of VFD, IMCC, resin pump etc. VFD diagnostic messages must be transferred to PLC through PROFIBUS.


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ix. The resin lining operation shall stop under any of the following conditions: a. For all the hardware segments, if segment stops rotating. This shall be sensed by

detection of movement of the non-driven roller by proximity switch. b. For NE and MS hardware segments, when the longitudinal travel of the Boom stops.

(This shall be detected by encoder for longitudinal travel of the boom.) c. For HE and NE hardware segment, the swivel motion of the Lance and longitudinal

travel of the Boom stops. This shall be detected by the encoder for the lance for swiveling motion and by encoder provided for longitudinal movement of the boom.

x. During the idle run of the Boom, the lance has to be located at 90°. This is to prevent the

interference of the Lance either with the Cabinet or with the segment during loading / unloading.

xi. In addition to the above the party shall provide all necessary interlock for the safe and reliable operations of the machine during resin lining of the Hardware at the time of actual program development. The above mentioned list of interlocks is tentative. Final list of interlocks will be provided to the Contractor at the time of actual program development.

IV. Codes and Standards

1. All equipment, systems and works covered under this specification shall comply with all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed.

2. In particular, the following standards are applicable (latest editions)

ANSI : American National Standards Institute

70.2 Control Valve Seat Leakage classification.

ASME : American Society for Mechanical Engineers

BS : British Standards

BS-5308 Part-I Specification for Polyethylene insulated cables.

IEC : International Electro technical Commission

IEC 79 Electrical Apparatus for Explosive Gas atmosphere

IEC-332 Test on bunched wires or cables.

IEC 529 Classification of degree of protection provided by enclosures

IEC 801 Electromagnetic compatibility for industrial for industrial Process measurement and control.

ISA : Instrument Society of America

S-5.2 Binary Logic Diagrams for Process Operations.

S-7.3 Quality standard for instrument air


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S-75.01 Flow equations for Control Valve Sizing

ISO : International Standard Organisation

ISO-5167 Measurement Of fluid flow in closed conduits

NEC : National Electric Code

NEMA : National Electrical Manufacturer’s Association

ICS-6

IEEE12207

Enclosures for industrial control system

Software Standards

IS: 13947.

IEC 326.

Low voltage switchgear and control gear : General rules Part-1

Printed Circuit Boards

3. Other national standards established to be equivalent or superior to the codes and standards specified are also acceptable. The CONTRACTOR shall furnish English translation of all standards specified in this specification.

4. In the event of any conflict between the codes and standards referred to in the specification and

the requirements of this specification, the more stringent of these requirements shall govern.

5. Unless indicated otherwise, all codes and standards referred to in this enquiry specification shall be understood to be the latest version on the date of offer made by the CONTRACTOR.


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V. I & C System Configuration, Panels and Other Details

1. I&C Configuration

i. Proximity sensors for following status indication shall be provided. (a) For the front covers of the Blast Cabinet, Home position of Boom inside the Blast

Cabinet, End positions of the cylindrical section of Head End, Middle and Nozzle End segments (to limit over-travel of the Boom), end covers, segment identification, detection of movement of non-driven rollers for the segments, detection of movement of non-driven rollers for the boom travel in Blast Cleaning System.

(b) For the front covers of the Degreasing Cabinet, Home position of Boom inside the Degreasing Cabinet, End positions of the cylindrical section of Head End, Middle and Nozzle End segments (to limit over-travel of the Boom), end covers, segment identification, detection of movement of non-driven rollers for the segments, detection of movement of non-driven rollers for the boom travel in Degreasing System.

(c) For the Home position of Boom, End positions of the cylindrical section of Head End, Middle and Nozzle End segments (to limit over-travel of the Boom), segment identification, detection of movement of non-driven rollers for the segments, detection of movement of non-driven rollers for the boom travel in Resin Lining System.

ii. Encoder (Detailed Specification of the encoder has been provided in the annexure) for following movements in all the three machines shall be provided

(a) The longitudinal travel of Boom. (b) The swiveling motion of the Lance. (c) These must be interfaced with Siemens make SM338 special function modules.

iii. Inlet pressure to blast generator must be monitored using pressure transmitter.

iv. Pressure Transmitters shall be provided at the outlet of TCE Spray Pump. Level Gauges, Level Switches, Temperature Elements for TCE storage tank and TCE collection vessel shall also be provided.

v. All instruments required for reliable & safe operation of all the three machines shall be

provided.

vi. Provisions must be made in such a way that the machine can be controlled from all the individual dedicated MMIs as well as backup MMIs and clients. SCADA should have all the provisions to log data, events, alarms as well as interlock failures.

vii. All the quantities mentioned in the annexure are indicative and the exact quantity may vary based on the site conditions and process requirements. Any device or components which is not mentioned above but essentially required for the completion of system is in the scope of the contractor.


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2. Operator Panel and other subsystems

i. Two modular operator panels (1.Common for blast cleaning and degreasing and 2. For Resin Lining),with IP-65 protection ,which will house MMIs shall be provided for control & monitoring of grit blast cleaning, degreasing and resin lining operations.

ii. Supply, erection and commissioning one no. of completely wired Control Panel each for Blast Cleaning, Degreasing and Resin Lining systems as per the G.A drawings approved by Department. Control Panel for all the three systems shall be PLC (Programmable Logic Controller) based. The Control Panel shall be fully wired with Isolators /multipliers, Relays,MIL-26482 qualified circular multi-pin connectors etc. The Control Panel shall be located inside the Room, away from the machines.

iii. PLCs for all the three systems shall be standalone. It must be linked with dedicated MMIs as well as backup MMIs and clients.

iv. Following drawings/documents shall be used as guidelines for design of the Control Panel: (a) Typical Digital Signal – Hardware Facility – Digital input scheme (b) Typical Digital Command Loop – Hardware Facility – Digital output scheme (c) Typical Analog measurement Loop –Hardware Facility – Analog input scheme (d) Typical Analog Command Loop – Hardware Facility – Analog output scheme (e) Typical Encoder Loop – Hardware Facility – Position Control scheme (f) Specifications in Annexure-2

v. PLC system shall be interfaced with SCADA system (installed in MMIs which are housed in Operator panel) using suitable network switches and Ethernet cable.

vi. Specifications of panels are attached in the Annexure.

vii. There shall be three modes of operation of for all the three machines : (a) Auto mode: In auto mode the various positions control loops shall be started/ stopped

automatically in a sequence by operation of ‘Process start’ & ‘Process stop’ pushbuttons as per definitions in the program.

(b) Manual: In manual mode, the entire program is divided into different segments and each segment can be operated independently. Auto and Manual mode of operation shall be provided with same set of safety interlocks.

(c) Further Dry mode of Operation is required to operate the sub systems independently without any interlocks

(d) The detailed program sheet will be provided at the time of program development.

viii. PLC must communicate with VFD drives, IMCC, weighing system (only communication part) and pressure transmitters through PROFIBUS interface. All the commands and diagnostics from VFD and IMCC must be captured in PLC.

ix. All the electronic components shall be suitable for coastal area installations.


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x. The total operational data available on system must be non-volatile during power break down.

xi. PLC’s must have suitable Ethernet interface for connecting with SCADA MMIs. They must also have suitable PROFIBUS interface to interact with the drives.

xii. All the electronic components shall be suitable for coastal area installations.

xiii. The total operational data available on system must be non-volatile during power break down.

xiv. Interfacing with Electrical Systems:

The necessary potential free points for ICS system, DI/DO, AI/AO will be planned in MCCB/MPCB/Contactors in Electrical panel. Necessary cabling from ICS rack to/from MCC (until TBs) is in the scope of supplier. Laying of PROFIBUS cable and configuration of VFD/SIMOCODE to ICS rack is also in the scope of supplier.

xv. Interfacing with IMCC PRO V communication module along with basic unit, Make: Siemens, Model : SIMOCODE Rating : As per the motor rated capacity. (Note: The interfacing of SIMOCODE with DACS system is in the scope of supplier. Supply of SIMOCODE is NOT in the scope of supplier.) The SIMOCODE interfacing with PLC will be through PROFIBUS. Instrumentation and Control system shall be designed such that all the motor related parameters (like current, voltage, trip status, etc) of the feeder shall be displayed in MMI.

3. I&C Cables

i. Within the facility cables shall be laid in cable trays/ conduits supported on EPs on wall, column beams etc.

ii. In the Control Room the cables shall be laid in cable trays. iii. Cable glanding and termination is totally under Vendor’s scope.

4. Cable Glands The cable glands shall be of double compression type with high quality neoprene gaskets. Cable glands shall be SS on both sides of cable.

5. Cable trays Cable trays shall be perforated of hot dipped galvanized steel with powder coating. All cable trays shall be of 100 mm height. Cables within buildings shall be laid on cable trays supported on wall, column, beams etc. In Control Room the cables shall be laid in cable trays. (Cable tray supply and cable tray erection in Control Room shall be in the scope of Vendor.)


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6. Wiring i. All inter cubical and internal wiring for all Control Panels shall be carried out with 1100V

grade, stranded tinned copper conductors with HFFR insulation. The minimum size of the stranded copper conductor used for the panel wiring shall be 1.5 mm2 for 24 VDC control commands. For power supply, the conductor size shall be provided as per the load rating (min. 2.5 sq. mm for 230 V AC and 1.5 sq.mm. for 24 V DC). Control & Power wiring shall be segregated and routed in PVC troughs. Different colour wires shall be used for different voltages.

ii. Engraved core identification plastic ferrules, marked to correspond with the panel-wiring diagram shall be fitted at both ends of each wire. Cross ferruling shall be done.

iii. For termination of cables emanating/entering Control Panels MIL (MIL-26482 for 4-20 mA signal and MIL-5015C for 24 V DC) qualified multipin circular connectors shall be provided. Terminal blocks shall not be acceptable.

iv. All spare contacts and spare terminals of the panel mounted equipment and devices shall be wired to the connectors.

7. Cable Terminations For cables upto 1.5 sq.mm. Crimped pins shall be provided and for cable sizes above 1.5 sq.mm. Crimped lugs shall be provided suitable for terminating on MIL-26482 and MIL-5015C multipin circular connectors in Control Panel. All necessary cable terminating accessories such as removable gland plates, compression glands, supporting clamps and brackets, wiring troughs and gutters, etc. shall be included in the Supplier’s scope of supply.

8. Plug Points and Interior Lighting i. A 5/15 Amp 230V, 1 phase, 50 Hz, AC 3 pin plug point shall be provided in the interior

Control Panel with On/Off control switch and fuse. ii. For interior lighting 230V, 1 Phase, 50 Hz, 40W fluorescent lamp with operating door

switch and protective fuses shall also be provided.

9. Relays All interlocks and logics executed in Control Panel for interfacing commands with electrical panels and for multiplication of digital output signals relays shall be used. Relays of suitable rating shall be provided considering the load. Each Relays shall have minimum 4 changeover contacts.

10. Isolator All the analog output channels must be interfaced to PLC modules through Isolators. Isolators of suitable ratings have to be provided by the SUPPLIER.


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11. Labels All front mounted equipment, as well as equipment mounted inside the Control Panel shall be provided with individual labels with equipment designation engraved. These shall be Phenolic overlays (1.6 mm thick) with black background and white lettering and shall be fixed to the panel by stainless steel screws (counter sunk). The Control Panel shall also be provided at the top with a label engraved with the panel designation. Lettering for panel designation shall be 6 mm. The minimum lettering size for instrument/device labels shall be 3mm. The lettering on the labels shall be subject to Department’s approval. Labels of internally mounted equipment shall be clearly visible.

12. Earthing Control Panels shall be provided with a safety ground bus & system ground bus made of copper securely fixed along the inside base of the panels. These buses shall be typically of 25 mm wide and 6 mm thick of copper. The safety ground bus shall be properly secured to the plant safety earthing. All metallic cases/frames of relays, instruments, other panel mounted equipment shall be connected to the safety ground bus and shields & drain wires of signal/control cables shall be connected to the system ground bus by independent copper wires of not less than 2.5 sq. mm. The system ground bus shall be electrically isolated from AC mains earthing bus. The insulation colour code for earthing wires shall be green with yellow bands.

13. System Grounding i. Grounding of panels, junction boxes, power distribution boards & field instruments shall be

as per Grounding Scheme.

ii. Separate instrument signal and body earthing shall be provided for each field instrument. Single point earthing configuration shall be followed for the cable shields i.e. all data and control cables shields shall to be grounded at one end only to avoid ground loop.

14. I/O Count Blast Cleaning Machine

Blast Cleaning Machine

Digital I/P Digital O/P Analog I/P Analog O/P Special Function I/P

(Encoders)

55 25 0 2 2


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Degreasing Machine

Degreasing Machine Digital I/P Digital O/P Analog I/P Analog O/P

Special Function I/P (Encoders)

55 25 0 2 2

Resin lining Machine

Resin Lining Machine

Digital I/P Digital O/P Analog I/P Analog O/P Special

Function I/P (Encoders)

50 25 0 2 2

Above table shows actual I/O count required for all the three Systems. Contractor shall provided 20 % spare I/O’s of above I/O Count and wire them upto the connectors. Contractor shall consider additional I/O’s as per his system requirement and safety.

15. Drawings As per Annexure-1

16. Technical Specifications As per Annexure-2


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VI. Documents to be produced on acceptance of Purchase Order before start of fabrication.

1. Before Start of Procurement

Party shall provide the following Documents to SDSC SHAR within 4 weeks from the award of Purchase order for clearance.

i. Party shall produce the schedule of drawings and documents to be submitted for review,

approval and information with submission date.

ii. Party shall produce the configuration drawings for SHAR approval.

iii. Party shall convey Quality Assurance Plan (QAP)

iv. Detailed equipment list and bill of materials along with list of software licenses to be procured and DACS PCs specifications.

v. Supply of all required information for Design and configuration of Data Acquisition &

Control System Interface and related equipments.

vi. Operational Philosophy and Control logic for DACS.

vii. Instrument data sheets, loop diagrams and installation sketches with erection bill of quantities.

viii. Layout of Control Panel showing PLC modules, DCPS, and other instruments with construction details, foundation details and interior G.A. drawings.

ix. Front facia layout of Operator Panel as per G.A. drawings.

x. Instrument list with tag numbers, Makes and Model nos, Service and Type of Instruments.

xi. Control wiring diagrams indicating terminal details of each components, power supply distribution scheme and bill of quantities of all panel mounted instruments for control panels.

xii. Configuration of SCADA system.

xiii. Cable Schedule and Interconnection Schedule.

xiv. Electrical wiring diagrams showing interlocks, controls, wiring sizes, rating of each electrical component etc. and logic diagrams.

xv. Detailed description of operating sequence and control and interlock system .


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2 Final Documents after completion of fabrication:

Party shall submit the 3 copies of operation and maintenance manuals well before the despatch of the equipment. The manual shall be in sufficient detail of following

i. Step by step instructions to enable others to inspect erect, commission, maintain, dismantle, repair, reassemble and adjust all parts of the equipment.

ii. Each manual shall also include a complete set of approved as built drawings and P&I drawings together with performance / rating curves / charts of the equipment, maintenance schedule and test certificates wherever applicable.

iii. Final I&C as-built drawings, software codes and documents must be submitted by the

party(2 sets of hard copies as well as soft copies) .

VII. Scope of Inspection, Testing and Acceptance

1. Inspection,Testing &Acceptance of Instrumentation & Control System

A. General On the basis of guidelines specified in this specification Contractor shall submit their own testing, installation, commissioning and acceptance procedure. The procedure shall include purpose of test, test definition, results expected and acceptance criteria. All the procedures have to be reviewed and approved by Department.

B. Factory Acceptance Tests (FAT) i. Supplier shall demonstrate functional integrity of the various I&C items covered in this

specification. No material or equipment shall be transported until all required tests are completed & the system is ready for shipment by Purchaser.

ii. Purchaser reserves the right to involve and satisfy himself at each and every stage of testing. They shall be free to request specific tests on equipment considered necessary by them, although not listed in this specification. The cost of performing all tests shall be borne by the Supplier.

iii. Contractor to note that acceptance of any equipment or the exemption of inspection testing shall in no way absolve the Contractor of the responsibility for delivering the equipment meeting all the specified requirements.

iv. It shall be Contractor's responsibility to modify and/or replace any item if the specified functions are not completely achieved satisfactorily during FAT.

v. Contractor shall submit QAPs for all fields & panel mounted instruments, panels and all other items covered in the specification to Purchaser/ Consultant for approval. The FAT for the items shall be performed in accordance with the approved QAPs.


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vi. Testing and FAT for the Control Panel shall in general include the following minimum tests and reports shall be forwarded to the Purchaser: (a) Quality control test which shall be carried out to assure quality of all components. (b) Visual check of all instruments, IS isolator/multiplier, etc. mounted in the panels. (c) High voltage test as per relevant IS standard (d) Megger test (e) Functional testing. This shall include the simulation of each item in the Control

Panel supplied & wired by the Supplier and achieving the functional requirements as called for in the specifications. Checking of logic in the Control Panels shall be carried out.

vii. After the Contractor has performed the tests satisfactorily, the Contractor shall perform tests on the Control Panel to be witnessed by Purchaser as per approved QAP. Contractor shall notify the Purchaser at least one week prior to Factory Acceptance Test.

viii. All test certificates for testing instruments shall have calibration certificates from approved test house, valid for minimum 6 months.

C. Site Acceptance Tests (SAT)

i. Full integrated Site Acceptance Test shall be performed before hand over of total system to the PURCHASER. The test shall demonstrate functionality of the entire I&C system supplied & erected by the Contractor. The Contractor shall provide all personnel, test facilities, equipment and tools etc. for the same. All test instruments shall have calibration certificates from approved test house, valid for minimum 6 months. A test procedure is required for approval 2 weeks prior to the schedule start.

ii. Tests on cables (a) Check details are in accordance with the specification. (b) Check for physical damage. (c) Megger test between each core and armour/sheath. (d) Continuity check including screen continuity (e) Terminations in the instrument, Control Panel etc. supplied & erected by the

Contractor.

iii. It shall be ensured that erection Control Panel shall be as per approved layout drawings. Checking for tagging/identifications of Control Panel shall be done. Checks for continuity and termination of all power signal & control cables as per approved drawings shall be carried out. Control Panel supplied & erected by the Contractor shall be checked at site by carrying out the following tests: (a) Visual & Mechanical testing. (b) Checking of incoming power supply to the Control Panels. (c) Switching on the incoming supply to Control Panels.

iv. Tests on electrical installation


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(a) Checking of closing, tripping, supervision and interlocking of control devices. (b) Checking operation of all alarm circuits.

v. Test on complete control system. (a) On completion, the functioning of the complete control system shall be tested to

demonstrate its correct operation in accordance with the Specification.

(b) For control system testing, the Contractor may provide temporary means to simulate operating conditions, but the system will not be finally accepted until correct operation has been demonstrated to the satisfaction of the Purchaser when the complete Plant is operating.

D. Instrument Calibration.

i. The services of factory trained instrumentation technicians, tools and equipment for field calibration of each instrument to its specified accuracy in accordance with the manufacturer’s specifications and instructions for calibration shall be provided.

ii. Each instrument shall be calibrated at 0 %, 25 %, 50 % and 100 % of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 4 times greater than the specified accuracy of the instrument being calibrated.

iii. Such test instruments shall have accuracies traceable to the National Bureau of Standards as applicable.

iv. A written report on each instrument in the format required by the Purchaser shall be provided to the Purchaser certifying that it has been calibrated to its published specified accuracy. This report shall include a listing of the published specified accuracy and permissible tolerance at each point of calibration. The report shall be certified by the Engineer.

E. System Validation

i. The services of factory trained and field experienced instrumentation engineer(s) shall be

provided to validate each system and verify that it is operational and performing its intended functions as per specifications.

ii. Each system shall be validated by simulating inputs at the first element in loop (i.e. sensor) of 0 %,25 % ,50 % ,75 % and 100 % of span, or on/off and verifying loop output devices (i.e. indicator, alarm etc.).

iii. During system validation, provisional settings shall be made on position, levels, pressure, temperature, alarms etc.

iv. Correct operation of controllers shall be verified by observing that the final control element moves in the proper direction to correct the process variable as compared to the set point.


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v. All logic sequences shall be verified to operate in accordance with the specifications.

vi. All defects and malfunctions disclosed by tests shall be corrected immediately. New parts

and materials shall be used as required and approved and tests shall be repeated.

vii. A report certifying completion of validation of each instrument system indicating the errors observed during the validation and any provisional settings made to devices shall be provided. The report shall be made in the format required by the Purchaser and shall be certified by the Purchaser when he approves it.

F. Final Operational Testing and Acceptance. i. Upon completion of instrument calibration and system validation, all systems shall be

tested under process conditions.

ii. The testing shall include, but not limited to all specified operational modes, taking process variables to their limits (simulated or process) to verify all alarms, failures, interlocks and operational interlocks between systems and/or mechanical equipment.

iii. Any defects or malfunctions shall be immediately corrected using approved methods and materials and the tests shall then be repeated.

iv. Upon completion of final operational testing, a report shall be submitted, indicating that the total control system provided meets all the functional requirements specified herein. This report shall be made in the format required by the Purchaser. The Purchaser shall certify this report when he approves it and it shall constitute final acceptance of the control system

2. Commissioning,Trials,Final Acceptance and Training at SDSC,SHAR.

i. Automation systems shall be commissioned by Contractor’s engineers at SHAR. Commissioning Procedure shall be carried out in a methodical sequence as follows a. Start-up, b. Initial running, c. Operability adjustment, d. Stable operation e. Final adjustment

ii. After the entire installation work has been completed, the Contractor shall make all

required adjustments until all guaranteed performance requirements are met. All instruments, services required for the above tests shall be furnished by the Contractor. The test reports shall be handed over for Purchaser’s approval before handing over the plant.

iii. If the stipulated performance requirements are not fulfilled, the Contractor shall make good the deficiency by providing it in every case, by altering and/ or replacing the parts or the whole equipment / system free of charge to the Department immediately. All rejected equipment shall be removed from the site at Contractor’s expense.

iv. The Party shall conduct operation trials which include processing of DUMMY hardwares (all the six hardwares i.e. Head End, Middle segment and Nozzle end of PSOMXL and


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S139). The Contractor shall carry out all such operation trials as advised by the DEPARTMENT to ensure that design specifications are met and all equipment / system performs satisfactorily to meet guaranteed performance. Dummy segments to be provided by the SHAR

v. SHAR shall carry out process trials using actual hardwares. Contractor shall depute his supervisors during such process trials to assist the DEPARTMENT to ensure that design specifications are met and all equipment / system perform satisfactorily to meet the guaranteed performance. Duration of process trial could be maximum 3 months from the date of completion of satisfactory operation trial runs.

vi. Contractor shall depute their Technical team to provide Training to the SDSC,SHAR personnel.

3. Scope of Supplier includes the supply of following Items: All Instruments and Control System Equipments as described in Section II-Subsection 1 including the following.

i. PLC based Control Panel.

ii. Operator Panel (which houses HMI).

iii. All field instruments such as Proximity sensors, encoders etc.

iv. Instrument erection hardware, piping, fittings required between equipments and Control Panel.

v. Power and signal cables for connection between instruments/equipments and control panel.

vi. Cable laying from Control Panel/MCC to DACS cabinets and terminations.

vii. Cable laying from/to PLC to MMIs.

viii. Cable tray, conduit etc.

ix. DACS systems.

4. Terms and Conditions The scope of supply including but not limited to the following,

i. All the subsystems, systems, individual parts etc to meet the overall function of the

machine have been spelt out in this specification. The complete automation system, subsystems, parts there off must be realised by the purchaser to meet the overall functional requirements and specifications. If the Contractor is having any apprehension on the design


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to meet the overall functional requirements and/ or having suggestions to improve the functionality, efficiency, reliability and safety the same may be proposed and will be accepted subjected to the approval of purchaser, such proposal if any shall be spelt out in the offer document. In case the proposal is made after placement of order, the same shall be accepted subjected to review and approval by purchaser. Deviation from purchaser specification, if any shall be clearly brought out in the offer itself. In the absence of such clear spelling out of deviation, it will be presumed that the offer is fully and completely meeting the tender specifications.

ii. If PURCHASER desires to add or delete any item from Supplier’s scope of work, then the

total price shall be adjusted based on the unit rates furnished by the Contractor

iii. Any item/detail or work which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be furnished and erected, unless otherwise specifically excluded as indicated.

iv. All the necessary measuring and testing equipments required right from supply to final commissioning shall be in the scope of the Supplier.

v. It is not the intent to specify completely herein all details of design, supply, installation and commissioning of ‘automation systems’. However, the equipment, materials and services shall conform in all respects to high standards of engineering design, workmanship and be capable of performing in continuous commercial operation in a manner acceptable to the DEPARTMENT who will interpret the meaning of drawings and specifications and shall have the power to reject any ‘work/equipment’ or material which in his judgement are not in full accordance with the specification.

vi. Warranty of the machine to be provided for 1 year from the date of commissioning.


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VIII. Annexures

1. Drawings Digital Input Signal Loop:

Digital Output Signal Loop:


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Analog Output Signal Loop:

Encoder Signal Loop:


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Typical PLC Schematic


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Grounding scheme:


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SCADA CONFIGURATION


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Overall Schematic


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Annexure-2

Technical Specifications

Table 1 Specifications of Absolute Type Encoder

Description Essential Specification Make P&F Model AVM58N-011AAROGN-1212/ or any higher models. Operating voltage 10 ... 30 V DC Linearity ± 2 LSB at 16 Bit, ± 1 LSB at 13 Bit, ± 0,5 LSB at 12 Bit Output code Gray code, binary code Monoflop time 20 ± 10 µs Steps per Resolution: 4096 Multiturn 14 Bit Overall resolution up to 30 Bit Interface type SSI Transfer rate Voltage drop UB - 2.5 V 0.1 ... 2 MBit/s Standard conformity RS 422 Protection degree DIN EN 60529, IP65 Operating temperature -40 ... 85 °C (233 ..... 358 K) Installation Accessories Appropriate coupler and other devices necessary for

interfacing with motor and Special Function Module. Cable As per requirement Type of mounting Clamping flange Quantity 8

Table 2 Specifications of Pressure transmitter with local display

Description Essential Specification Make WIKA/Rosemount/SMAR/P&F Range 0-10bar Signal Output Profibus DP interface Power Supply 10-30 V DC Accuracy <0.3% of span Process Connection ½” NPT Display 7-segment LCD, 4 digit. Display Accuracy ±0.2% Quantity 2

Table 3 Specifications of Isolators

Description Essential Specification Make & Model P&F/KFD0-CS- 1.50

Type Analog Output Quantity. 8


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Table 4 Specifications of Proximity Sensor

Description Essential Specification Make P&F Model No NBB10-30GM40-Z0 or higher version

Type of proximity sensor Inductive type Sensing distance 10 mm Mounting location Safe area Type of mounting Threaded cylindrical type with check nuts Protection degree IP67 Nominal voltage Uo ... 24 V Hysteresis H 1 ... 10 typ. 5 % Indication of the switching state Yes Length of integral cable of 0.75mm2 with sensor (meter) 25 Quantity 150

Table 5 Specifications of solid state buzzer

Description Essential Specification Make Minilec Input 24V DC Output 96 to 104 db Range 50 meters Quantity 3

Table 6 Specifications of Phase Failure Relay

Description Essential Specification Make Minilac /Siemens voltage 240V AC Output NO-2nos. Quantity 4

Table No: 7 Specification of Level Switch

Description Essential Specification Make Minilec / Nievelco/Switzer/IFM Output contact NO/NC Contacts- 2 nos. Mounting location On the top of storage tank Sensitivity 1 k ohm to 200 k ohm adjustable Protection IP 66 Range: 1500 mm Fittings Required Cable Entry ½” NPT Female with double compression cable gland Body material, sensing element, fittings Suitable for corrosive environment Quantity 2


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Table 8

Specifications of RTD Sensor Description Description

Make Rosemount / ABB / Nagman / E&H / Yokogawa/ Omega Type of sensor Pt100,3 – wire Accuracy IEC 751 Class A & DIN 60751 Protection IP 67 Temperature Coefficient: 0.00385 Ohms/ 0C TemperatureRange: 0 to 120C Sensor wire PTFE insulated, Nickel coated copper stranded wire. Sensor Immersion length 500mm Thermowell Required Sheath Sensor shall be housed in ¼” SS 316 sheath Quantity 1

Table 9

Specifications of PID Controller Description Essential Specification

Range 0-100°C Make ABB/Honeywell/ Eurotherm Type PID Input Universal Output NO/NC Contacts- 2 nos. 230VAC, 5 A, Independent AC Relay

Outputs. Accuracy ±0.5°C Power Supply 230 V AC, 50 Hz. Display 5 Digit Dual, (for set point and process value) Quantity 1

Table 10 Specifications of Relay board

Description Essential Specification Make Omron/Phoenix/Wago/Telemachanique No of channels 8 Voltage 24V DC Quantity 36

Table 11 Specifications of Solenoid Valves

Description Essential Specification Make ASCO/LUTHRA/Norgren Type 3 way Size 2.4mm Pipe size ¼ inch BSP Operating pressure 5 bar Rated Voltage 24V DC Operation Normally closed Quantity 4


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Table No: 12 Specification of Float switch

Description Essential Specification Make Switzer / Honeywell / sigma / Danfoss Medium TCE Type Vane / paddle Switch type Micro switch Accuracy ± 2% of span Switch contacts DPDT Contact rating 5A ,250 V AC Switch setting Tamper proof and external adjustment Over range protection 1.5 times of Max. flow Protection IP 67 Cable Entry ½” NPT Female with double compression cable gland. Body material Brass Vane / Paddle material SS 304 four vane combination – vane length shall be adjustable and

shall be compatible with water pump flow rate Temperature of TCE 100°C Quantity 1

Table 13 Specifications of redundant DC Power Supply

Description Essential Specification Make Phoenix/Delta/ Siemens Output voltage 30 V DC ±20% (variable from 24 V to 36V by set 30V Output current 20A (continuously variable by CURRENT LIMIT

control) Line regulation CV CC

±0.02% ±2mV ±10% change in line ±0.05% ± 10mA

Load regulation CV CC

±0.02% +diode drop – for load change from zero to full load. ±0.05% ±10ma – for change on O/P voltage from 0V to 30V.

Ripple / noise CV CC

1mV r.m.s 5 mA r.m.s

Metering 3-digit panel meters are provided for measurement of voltage & current.

Protection Over voltage protection O/P fail Alarm

Automatic crossover type protection is provided against short circuit & over load. Crowbar type over voltage protection is provided. Potential free relay contact is provided on 7 way terminal board at rear panel

Operating temperature 0 – 50 C Input source 230V AC, ±10%, 50Hz, single phase Quantity 3nos. (main and redundant configuration with Diode

ORed)


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Table No: 14 Specification of Programmable Logic Controller

Description Essential Specification

Manufacturer Siemens

Type S7 315-2PN/DP (Model: 6ES7315-2EH14-0AB0) CPU(with latest hardware version and firmware) or higher.

Location Control room

Self diagnostics features Required for each and every module available in the PLC (i.e. CPU, PS, I/O modules, other communication interface modules etc).

Work memory 384 kb or higher Memory Card 2MB MMC

Interface for communication between PLCs and MMI

1) Ethernet Communication between PLCs and SCADA MMIs. 2) Profibus Communication between VFD, Pressure transmitters, Weighing

system and CPU. 3) Special Function Module for direct Interface with Encoder. 4) Bus structured architecture. 5) Max. 8 Nos. of I/O modules per node. 6) Maximum number of nodes shall be arrived as per the I/O list.

Quantity 3 Note Product life cycle of the selected CPU version should not be less than 10 years

from the date of commissioning.

Table No: 15 Specification of Input / Output modules

Description Essential Specification Manufacturer Siemens Type S7 300 series I/Os Location Service room

Self diagnostics features Required for each and every module available in the PLC (i.e. PS, I/O modules, other communication interface modules etc).

Type Model No. Quantity

4 Channel Analog Output module 6ES7-332-5HD01-0AB0 (or higher model)

4

16 Channel Digital Input module 6ES7-321-7BH01-0AB0 (or higher model)

15

16 Channel Digital Output module

6ES7-322-5GH00-0AB0(or higher model)

8

Special Function Module 6ES7 338-4BC01-0AB0(or higher model)

4

Power Supply Module 24V,5A 6ES7-307-1EA01-0AA0(or higher model)

7

Interface Module IM360 6ES7 360-3AA01-0AA0 (or higher model)

4


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Interface Module IM361 6ES7 361-3CA01-0AA0(or higher model)

4

Communication Processor (ISO/Profinet) CP343-1

6GK7 343-1EX30-0XE0(or higher model)

4

Accessories • Backplane for housing CPU, Power Supply and Modules • Connectors for all the I/O Modules

Table 16 Specifications of panels

Description Essential Specification Manufacturer Rittel/Schneider/Amaraja. Service Housing PLC, I/O modules, DCPS, Isolators, Relays etc. Location Control room Type Free standing Cable entry Rear entry Door Required

Front & rear door : Double leaf lockable Concealed type hinges & a 180 degree swing.

Temperature Ambient to 50 Deg C Painting Inner : Glossy white color

Outer: Siemens grey color (RAL7032) Mounting and wiring MIL -26482 qualified circular multipin connectors Quantity 3 Enclosure Degree of protection : IP 40 as per IS 13947

Dimensions : As required Material Sheet material thickness: CRCA-COLD rolled 2mm

Gland plates thickness : 3mm Gasket for door & cover: neoprene Plugs for spare cable entries: required

Channels Shall provide with bolt & nut Anti-vibration pads 15 mm thickness Blower Required, in each section with brass mesh. Louvers Required, with fine brass wire mesh in each door/section Light Fluorescent lamp Lifting Eye-bolts Plugs For incoming & outgoing Metal tag name plate Required Clamps Required Fixtures Required Bolts, nuts & gaskets Required Lock & key Required

Spares

• 20 % spare entries to be provided for incoming & outgoing cables.

• 20 % spare for terminal blocks. • 20 % spare space for future requirement.

Note: Specifications mentioned here are only for control panel (One for each system). Two Modular operator panels; viz.: One which will be common for blast cleaning and degreasing systems to house MMIs and Two for Resin Lining system are to be provided by the vendor.


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Table 17 Specifications of Signal Cables & Control Cables

Description Essential Specification Manufacturer UNIFLEX, THERMOCABLES, NICCO, Deccan, Delta, Lapp, Paramount

cables , Code used BS-5308 Signal Cables Control Cables Conductor 0.5 Sq.mm annealed tinned copper

conductor of 7 strands. 1.0 Sq.mm annealed tinned copper conductor of 14 strands.

Primary insulation XLPE insulated core. No. of twists/meter Minimum 20 twists/meter N/A Core identification By colour With numbers at interval of not

more than 250 mm as per vendors standards.

Voltage grade 1100 V

Cable identification Running length of the cable shall be printed at least at every 5 meter interval.

Pair identification With numbers at interval of not more than 250 mm as per vendors standards.

N/A

Shielding Individual + Overall: Aluminium Mylar tape & ATC drain wire with PTP tape.

Overall: Aluminium Mylar tape & ATC drain wire with FG tape.

Drain wire size 0.5 Sq.mm

Drain wire material Multi -stranded bare tinned annealed copper in continuous contact with aluminum side of the shield.

Drain wire resistance Drain wire resistance including shield shall not exceed 40Ω/km

Tape thickness 0.05mm

% coverage / overlap 100% / 25%

Inner sheath Extruded Black FRLS PVC type ST-2.

Armouring Galvanized steel round wire.

Outer sheath Extruded flame retardant 90 °C PVC to IS-5831 type ST-2/IEC 502. Color light blue.

a) PVC oxygen index: over 30% b) PVC temperature index: over 250 °C c) Fire retardant: yes, as per IEC-332 part3, CAT A d) Smoke density: 0.6 e) Acid gas emission: 0.2

Electrical properties @ 20 °C

1) Conductor resistance: maximum 40Ω/km.

Conductor resistance: maximum 20Ω/km.

2) Insulation resistance: minimum 5000M Ω. 3) Mutual capacitance: maximum 75pF. 4) L/R ratio: maximum 25µH/ Ω. 5) Test voltage: 5.1) Conductor to conductor: 1000 V for 1 minute.

5.2) Conductor to shield & Armour: 1000 V for 1 minute. Tests All the tests shall be conducted as the part of pre-delivery inspection. Quantity As per the requirement


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Table 18

Specifications of MMI Description Essential Specification

Manufacturer HP, Dell, Sony, Samsung

Processor INTEL CORE i7 (third generation) above 2.5 GHz

Hard disk capacity 1TB

Motherboard INTEL original (Suitable for the configuration) Must have min. 4 PCI slots for incorporating Ethernet cards.

DDR RAM (DDR3) 8 GB (2 x 4GB)

Network cards Ethernet card:1 Nos. (100Mbps/1Gbps)

Optical Drive DVD RW (Multi layer)

Ports (other than those required for connecting monitor, keyboard and mouse)

Ethernet ports: 4 Nos USB: Minimum 3 Nos. (with at-least one USB 3.0) Other cards such as PROFINET has been mentioned in TABLE 19

Power supply Suitable 230V AC 50Hz

Operating system Licensed version of Windows 7 ultimate Retail edition.

Monitor Screen 24”, supported resolution 1280x1024 and above.

Optical Mouse (additional) Standard USB Mouse with scroll.

CD’s for all software & drivers Required.

Quantity 7 Nos.

Note: - All the components shall be of reputed make.

Softwares to be supplied along with MMIs: • Licensed copy of latest version of Nero smart CD/ DVD RW software in all MMIs. • MS Office 2012 Professional in all the standalone MMIs. • Licensed and Latest version of ‘Adobe acrobat’ read & write software in all MMIs. • One Licensed version of Microsoft SQL latest version. • One Licensed version of SIMATIC Step 7 (latest version) with SIMATIC Manager 5.5 or latest

version. • 1 No. of PLC Simulator and SIMATIC NET softwares. • Any other necessary License required to configure PLC-to-peripherals and SCADA communication

shall be provided.


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Table 19 Specifications of Communication Cards

Description Essential Specifications Type PROFINET/ISO Ethernet Communication Cards for MMIs Make Siemens Quantity As per the requirement

Table 20 Specifications of Network Switch

Description Essential Specifications

Type Manageable, Layer-2 Fast Ethernet switches with inbuilt fiber optic convertor.

Make Cisco, Cabletron, MRV, Entrasys, D-Link, MOXA, Siemens

Number of Ports Minimum 24 ports (100Mbps/1Gbps) full duplex electrical ports. Uplink-4 ports (1Gbps)

Auto sensing & Auto-negotiating ports Required SNMP management feature Required Power 230 V AC

Diagnostics LEDs for power, duplex mode indication, flow control activation, collision indication (when working in half duplex), CRC indication

Security Port security Quality of service Required Spanning tree protocol Required Associated software Required of the same make as the Ethernet switch Type of communication on LAN Ethernet, IEEE 802.3u Communication Protocol for LAN TCP/IP Virtual LAN capability Required Operating temperature Up to +60 C

Quantity 24 port-1 no. 8 port-1 no.

Notes:-

• RJ-45 connectors shall be provided for the electrical connections from MMIs, CPU etc. using CAT 7e cables to Layer-2 Ethernet switch.

• Supplier has to provide armoured Ethernet cable to connect MMI’s and PLC to centralized server.


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Table 21 Specifications 230V AC Uninterruptible Power Supply (UPS)

Description Essential Specification Make Numeric power systems limited/ APC/Schenider

Rating 6KVA

Input braker 32Amps / 250V AC

External battery 240V,24A

Redundancy configuration 2 Nos. of UPS in Parallel redundant configuration.

Bypass line conditioners Isolation transformers and Servo Stabilizers shall be provided

Output power factor 0.8

Output wave form Pure Sine wave

Communication interface

1. RS232 port for software interface 2. SNMP Management (Web enabled interface) 3. Parallel port for communication with other UPS in N+1

configuration

Battery type Sealed Maintenance Free Lead Acid

Battery backup time 30min @ full load.

Technology On-line double conversion with advanced digital signal processor technology

Output Termination Output line must be routed through MCB.

Stabilizer

Capacity 6KVA

Input 195-265 V AC

Output 230VAC